Imagine wearing a glove that makes lifting heavy objects easier or a lightweight robotic suit that helps people regain movement after an injury. These futuristic ideas depend on one important technology: artificial muscles. Scientists around the world have been working to create materials that can move like real muscles while remaining lightweight, flexible, and energy-efficient.
Now, researchers led by Maki Hiraoka have developed a new type of coiled fibre actuator that could bring these technologies much closer to everyday use. Their design uses a common plastic material called linear low-density polyethylene (LLDPE) and delivers impressive performance while operating at much lower temperatures than previous fibre actuators.
The new invention could lead to more practical wearable devices, soft robots, medical equipment, and assistive technologies.
What Is a Fibre Actuator?
A fibre actuator is a special material that behaves somewhat like a muscle. When heated or electrically powered, it contracts, expands, or twists to produce movement.
Unlike traditional electric motors, fibre actuators are:
Lightweight
Flexible
Easy to integrate into fabrics
Suitable for wearable technology
Quiet during operation
Because of these advantages, researchers believe fibre actuators could become the foundation of future soft robotics and wearable assistive devices.
However, one major challenge has limited their widespread use.
The Problem with Earlier Artificial Muscles
Many existing coiled fibre actuators require high temperatures to operate effectively.
High operating temperatures create several problems:
They consume large amounts of electricity.
They can damage clothing and wearable fabrics.
They reduce user comfort.
They increase safety concerns.
They are harder to integrate into soft robotic systems.
For wearable devices, lower operating temperatures are extremely important because the actuator must work safely while remaining close to the human body.
A New Material Makes the Difference
The research team solved this problem by creating their actuator from highly drawn hard LLDPE fibres.
LLDPE is already widely used because it is:
Strong
Flexible
Lightweight
Inexpensive
Easy to manufacture
The researchers twisted these fibres into compact coils, creating an actuator capable of producing large movement with surprisingly little energy.
Operates at Only 60°C
One of the biggest achievements of this new actuator is its low operating temperature.
Instead of requiring extremely high heat, it begins operating at temperatures as low as 60°C.
This offers several important benefits:
Lower energy consumption
Greater safety
Better compatibility with wearable fabrics
Longer material life
Easier integration into soft robotic systems
Since ordinary textiles can tolerate these temperatures, the actuator can be built directly into clothing without causing thermal damage.
Uses Much Less Power
Energy efficiency is another major improvement.
The researchers found that their actuator requires only 20% of the electrical power used by earlier coiled fibre actuators while producing the same mechanical stress of 20 megapascals (MPa) at 10% strain.
In simple terms, this means the actuator performs similar work while using about 80% less energy.
For battery-powered wearable devices, this could significantly increase operating time while reducing battery size and weight.
More Powerful Than Human Muscle
Perhaps the most exciting result is the actuator's remarkable performance.
At relatively low temperatures, it achieved:
1600 watts per kilogram of specific power
69 MPa tensile stress
2% work efficiency
To understand how impressive this is, the researchers compared it with human skeletal muscle.
The actuator produces:
Around 8 times more specific power
About 230 times greater tensile stress
This does not mean it is stronger than the human body in every way. Human muscles remain far more efficient, adaptable, and capable of continuous movement. However, these numbers show that the artificial fibre can generate an exceptionally large amount of force for its size and weight.
Large Movement Despite a Compact Design
Another remarkable feature is how much the actuator can move.
When heated from 30°C to 90°C, the fibre generated strains as high as 23%.
Strain refers to how much the material changes length during movement.
Achieving such a large strain is especially impressive because the fibre is tightly coiled into a compact shape. Normally, compact actuators sacrifice movement for strength, but this design manages to provide both.
This combination of compact size and large motion makes it highly attractive for wearable technologies where space is limited.
How Does It Work?
Instead of using bulky external heaters, the actuator operates through electrical resistance heating.
When electricity flows through the system, the fibre warms up and contracts, producing movement.
This approach offers several advantages:
Fast response
Simple electrical control
Easy integration into wearable electronics
Reduced mechanical complexity
Since it only requires moderate heating, it consumes much less energy than previous designs.
Safe for Clothing and Wearable Devices
Because the actuator works at relatively low temperatures, it can be combined with many common materials used in wearable technology.
These include:
Regular fabrics
Stretchable conductive elastomers
Flexible electronic components
Previous actuators often generated enough heat to damage surrounding materials.
The new LLDPE actuator avoids this problem, making it much easier to create comfortable wearable devices.
Understanding the Science Behind the Performance
The researchers also investigated why the material performs so well.
Using nanostructural analysis, they discovered that tiny crystal structures inside the drawn LLDPE fibres are connected only by weak bridges.
These weak connections allow the fibres to twist easily into compact helical coils during manufacturing.
Later, when heated, these structures deform efficiently, allowing the actuator to generate large movement while using relatively little energy.
This microscopic structure is one of the key reasons for the actuator's excellent performance.
Possible Future Applications
This technology could support many exciting future innovations.
Some possible applications include:
Soft robotic hands
Medical rehabilitation devices
Power-assisted gloves
Smart clothing
Wearable exoskeletons
Industrial assistive suits
Flexible robotic systems
Human motion assistance
One demonstration already showed the actuator working inside a power-assisted glove.
Although still at an early stage, the researchers believe future versions can become even better through improved thermal insulation and more advanced textile designs.
Challenges Still Ahead
Despite the promising results, more work remains before these actuators appear in commercial products.
Researchers still need to improve:
Long-term durability
Repeated heating and cooling performance
Large-scale manufacturing
Overall system efficiency
Integration with complete wearable electronics
These challenges are common for emerging wearable technologies and are expected to improve with continued research.
A Step Toward Smarter Wearable Robotics
The new coiled LLDPE fibre actuator represents an important advance in artificial muscle technology.
By combining low operating temperatures, low energy consumption, high power output, and large movement, it overcomes several major limitations of previous fibre actuators.
Its ability to operate safely with ordinary fabrics makes it especially attractive for wearable robotics, assistive clothing, and medical devices. As researchers continue refining the design, this technology could help create the next generation of lightweight robotic wearables that are more comfortable, more efficient, and practical for everyday life.
While commercial products may still be some years away, this research demonstrates that powerful artificial muscles no longer need extreme temperatures or high energy consumption. Instead, they can be built from simple polymer fibres and integrated into wearable systems, bringing the vision of smart robotic clothing one step closer to reality.
Reference: Hiraoka, M., Nakamura, K., Arase, H. et al. Power-efficient low-temperature woven coiled fibre actuator for wearable applications. Sci Rep 6, 36358 (2016). https://doi.org/10.1038/srep36358

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