A Lightweight Perching Gripper That Helps Drones Save Energy While Staying in Place

At a Glance

Researchers at Colorado State University have developed a lightweight and energy-efficient gripper that allows aerial robots to perch and grasp objects such as trees, roofs, and power lines. The mechanism helps drones conserve power by resting at elevated locations instead of continuously hovering. The gripper is easy to activate, stable while holding weight, and adaptable for different robot sizes and payloads. Built from low-cost 3D-printed materials and flexible joints, the design supports rapid customization and economical manufacturing.

Background

Small aerial robots are increasingly used in areas such as scientific research, infrastructure inspection, recreation, and defense. However, limited battery life remains a major challenge, especially for multi-rotor drones that often operate for less than an hour before recharging. One way to extend operational time is to allow drones to perch on nearby structures while continuing to monitor their surroundings. Existing perching systems can be mechanically complex, heavy, or difficult to adapt to different environments, creating a need for simpler and more energy-efficient solutions.

Overview

This technology introduces a bistable gripper mechanism that enables aerial robots to transition between open and closed states for perching and grasping. The gripper closes automatically when impact force is applied during contact with a surface or object, allowing the drone to quickly secure itself without continuous power consumption. Releasing the gripper can be achieved either through resistance-wire heating or a motor-driven lever system. The design supports both clipping-style perching, which relies on friction, and encircling-style perching, where the fingers wrap around an object for a more secure hold.

The mechanism is constructed using lightweight 3D-printed polylactic acid (PLA) components combined with commercially available silicone tubing that acts as compliant joints. This approach reduces manufacturing cost while making it easier to modify the gripper for different aerial robots, payload sizes, and operational requirements. The researchers also developed mathematical models that characterize the activation forces required for proper operation and provide design guidelines for tuning the gripper’s performance for different applications.

Benefits

Reduces drone energy consumption by enabling perching instead of continuous hovering
Lightweight construction suitable for small aerial robots
Low-cost fabrication using 3D-printed materials and commercially available components
Stable grasping capability for both perching and payload handling
Easily adaptable for different drone sizes and payload requirements
Supports multiple perching styles, including clipping and encircling grasping
Rapid and economical prototyping of customized designs
Flexible mounting options above or below the aerial robot