The Expanse: Advances in Design, Optimization, and Simulation of Linkage-Based Systems

<p dir="ltr">The performance of modern robotic systems is often attributed to limitations in control algorithms, computational resources, or model complexity. As a result, robot design has converged mainly on serial-chain architectures, which are straightforward to model, optimize, and simulate using existing tools. However, this focus overlooks the potential of more complex mechanical structures, where geometry, composition, and compliance can produce desired behaviors with minimal reliance on advanced control or computation. In aerospace, such designs have proven critical for missions like the James Webb Space Telescope, though they typically require extensive physical testing to ensure reliability. This thesis enhances the capabilities of linkage-based structures by introducing hierarchical composition, efficient optimization methods for high-dimensional design problems, and a data-driven physics-based digital twin framework for linkage analysis. Collectively, these contributions expand the design and analysis toolkit for mechanical systems in both robotic and aerospace applications.</p>