Abstract
Electroadhesive (EA) clutches are promising for advanced motion and force control in robotics, haptics, and rehabilitation, owing to their compactness and light weight. However, their practical use is limited by the inability to deliver high forces at low voltages, primarily due to a lack of understanding of their mechanics. We introduce a novel deformable body fracture mechanics approach and high-resolution strain field imaging to reveal that nonuniform stress distributions cause EA clutches to fail through delamination and crack propagation. Using this insight, we developed EA clutches sustaining 22 newtons over 1 square centimeter at 100 volts, achieving the highest stress per voltage among similar clutches. This was achieved by incorporating a soft interlayer and peeling stopper for uniform stress distribution and mitigating the failure modes. These EA clutches were integrated into a lightweight ring-based wearable system for finger rehabilitation and haptics. Our findings lay the groundwork for designing low-voltage, high-performance EA clutches for next-generation motion and force control applications.