Compliant revolute joints (CRJs) offer advantages in terms of frictionless motion, compactness, and monolithic fabrication, but their practical application is often constrained by an inherent stiffness–flexibility trade-off. High rotational compliance is typically accompanied by insufficient resistance to off-axis deformation, leading to parasitic motion and reduced directional stability. To address this challenge, this study proposes a hybrid CRJ designed to enhance directional stiffness while maintaining large elastic rotational capability. The joint integrates stiff polylactic acid (PLA) reinforcement ribs within a compliant thermoplastic polyurethane (TPU) matrix, with material distribution strategically tailored to suppress off-axis deformation without compromising the intended rotational motion. The design is compatible with monolithic fabrication via dual-material fused deposition modelling (FDM). Finite element analysis, informed by experimentally characterised material and interfacial properties, is employed to evaluate the mechanical performance of the proposed joint. The results demonstrate that the hybrid joint exhibits a significantly higher ratio of off-axis to on-axis rotational stiffness compared with mono-material PLA and TPU joints, indicating effective suppression of parasitic deformation while preserving rotational compliance.
compliant revolute joints; hybrid-material design; off-axis to on-axis stiffness ratio; dual-material fused deposition; finite element analysis