A Reconfigurable Design Approach for Hybrid Tendon–Pneumatic Continuum Robots Enabled by Soft Multi-Lumen Backbones

Continuum robots offer inherent compliance and dexterity for operation in confined and unstructured environments; however, achieving hybrid multi-segment functionality typically requires application-specific redesign and tightly coupled architectures. To address this limitation, this study proposes a reconfigurable hybrid continuum robot architecture based around a multi-lumen central integration backbone that supports multiple actuation modalities and robot configurations. The proposed design combines external tendon-driven disk modules for proximal actuation with a pneumatically actuated distal tip, while internal lumens allow routing of pneumatic lines and the insertion of optional stiffening elements without structural interference. The reconfigurability of the architecture is demonstrated through two configurations: Concept-1, a two-segment hybrid system, and Concept-2, a miniaturized three-segment configuration achieved by reducing the disk diameter and extending tendon actuation to the backbone. Experimental evaluations are conducted to characterize segment-wise actuation, coupled deformation behavior, and workspace capabilities, hysteresis response, tip contact force, and phantom-based target reachability. Results show that the integration of tendon-driven and pneumatic actuation significantly expands and reorients the reachable workspace. Additional functional tests showed repeatable loading–unloading behaviour of the tendon-driven segment, a maximum pneumatic tip contact force of approximately 0.45 N, and successful access to five representative targets within a stomach-like phantom using Concept-2. A kinematic model based on a constant-curvature formulation is validated against experimental data, yielding root-mean-square errors (RMSE) of 5.44 mm and 6.12 mm for Concept-1 and Concept-2, respectively. These results demonstrate consistent model accuracy across different configurations and scales. Overall, the proposed architecture enables modular, scalable, and reconfigurable hybrid continuum robots, providing a flexible framework for applications ranging from large-scale manipulation to gastroscopy-inspired minimally invasive procedures.