The Bionic RoboSkin project, funded by the German Federal Ministry of Education and Research (BMBF) under grant number 16ES0915 and administered by VDI/VDE Innovation + Technik GmbH, set out to create a flexible, three‑dimensional sensor skin that can be mounted on robotic platforms for autonomous navigation and service tasks in harsh environments. The core technical achievement is a textile‑based substrate that integrates sensor modules, electrical interconnects, and protective coatings into a single, modular system. The skin is designed to be used both underwater and on land, enabling the development of the autonomous robots “Manta” and “Dachs” for difficult‑access and hazardous‑area operations.

The project’s eight interlocking work packages culminated in a fully functional prototype. A key milestone was the development of a robust sensor‑module interface that couples a sensor carrier frame to a textile conductive trace. This interface allows the attachment of multiple sensor types—pressure, temperature, and strain gauges—while maintaining electrical integrity under repeated bending. The textile conductive traces were produced by combining weaving, warping, and embroidery techniques, each adapted to the specific conductive yarns used. The weaving process was modified to accommodate high‑conductivity fibers, and warping was employed to create flexible, high‑strength paths. Embroidery was used for fine‑scale patterning of sensor pads, enabling precise placement of individual sensor elements.

Mechanical durability was verified through a series of standardized tests. A flexometer measured the skin’s ability to withstand repeated bending cycles; the prototype maintained signal integrity after 10,000 flex cycles at a bending radius of 5 mm. Abrasion resistance was assessed with a Martindale abrasion tester, where the skin endured 20,000 cycles without significant loss of conductivity or sensor performance. A knick‑break test confirmed that the textile substrate could tolerate sharp bending without cracking, a critical requirement for underwater deployment where the skin may contact irregular surfaces.

Electrical performance was evaluated by integrating the sensor modules into a wireless sensor network. The network achieved a data transmission range of up to 30 m in an open environment and maintained a packet loss rate below 2 % under typical operating conditions. Power consumption of the integrated sensors was kept below 5 mW per module, allowing the skin to be powered by a small, onboard battery for extended missions. The modular design permits rapid reconfiguration; sensor modules can be swapped or added without re‑fabricating the entire skin, reducing development time for new robot platforms.

The project’s collaborative framework involved several partners. The Technical Institute for Textile and Textile Engineering (TITV) Greiz supplied expertise in conductive and functional textiles, developing new high‑conductivity yarns and processing methods. Other research institutions contributed to sensor design, wireless communication protocols, and mechanical testing. The project spanned three years, from initial concept to prototype validation, and was supported by the BMBF’s Innovation + Technology funding stream. Key personnel included project managers Lars Lindstaedt and Josephine Schuppang, who coordinated the interdisciplinary efforts and ensured compliance with funding requirements.

In summary, the Bionic RoboSkin delivers a versatile, durable, and electrically robust textile sensor skin that can be integrated onto robotic platforms for autonomous operation in challenging environments. Its modular architecture, proven mechanical resilience, and efficient sensor network make it a promising solution for future underwater and terrestrial robotics applications.