image: (A) Wearable device for the antennae: (i) A 3D model of the cockroach’s head was used as a reference to design the wearable device for the antennae. (ii) Two hooking mechanisms were incorporated to ensure the device attaches firmly to the cockroach’s head while also providing a secure connection at the antennae’s scape. The prototype was manufactured using a 3D printing method and tested for its attachment capability on a live cockroach. (iii) The improved design with 2 types of materials: the blue part is made with normal resin, the green part is made with active precursor resin that will be plated to conduct electrical stimuli, and a groove was added to separate the left and right parts of the antennae. (B) The prototype of wearable device was manufactured using a 3D printing method and was mounted on the head of the cockroach with the 2 connectors attached to the antennae. (C) The first design of the wearable device for the abdomen segments: (i) This design uses a hooking mechanism with pointed edges that are angled for easy attachment at the edges of the cockroach’s abdomen segment. (ii) The wearable device can firmly attach to the segment because pressure force is created because the gap between the upper and lower parts of the hooking mechanism is smaller than the thickness of the abdomen segment. (D) The improved design of the wearable device for the abdomen segments: (i) We modified the hooking mechanism to utilize hooks that clamp onto the edge of the tergum rather than relying on friction from pointed edges. (ii) This design integrates 3 main functions—the U-shaped clamp, the overlapping structure of the tergum, and the gripping hooks—which can cooperate to firmly fix the wearable device on the cockroach’s abdominal segment. (E) The prototype was manufactured using a 3D printing method and was attached to the second and sixth abdominal segments of the cockroach.
Credit: Hirotaka Sato, School of Mechanical and Aerospace Engineering, Nanyang Technological University.
Conventional approaches to cyborg insect preparation involve cutting antennae or cerci (sensory appendages) to implant electrodes, or using adhesives (like poly ionic liquid gels) to attach noninvasive films. “The methods have flaws: (1) Invasive implantation irreparably damages sensory organs, reducing the insect’s ability to detect obstacles and navigate; (2) Adhesive-based films degrade over time, cause exoskeleton harm during removal, and require skillful application—extending preparation time and limiting reuse; (3)Ethically, cutting appendages violates the “3Rs” framework (Replacement, Reduction, Refinement) for humane animal research, raising concerns about animal welfare.” explained study author Hirotaka Sato.
Researcher designed two key wearable components—headgear for antenna stimulation and abdominal buckles for acceleration control—that attach securely without adhesives or injury, preserving the insect’s natural functions. Antennae are critical for insects to sense obstacles, odors, and airflow. The researchers targeted the scape—the sturdy, base segment of the antenna—to avoid disrupting the more sensitive pedicel and flagellum (which house sensory receptors). The headgear features: (1) C-shaped elastic connectors: These grip the scape tightly, transmitting electrical signals without penetration. The elastic material expands temporarily during attachment, ensuring a snug fit; (2) Triangular hook mechanism: Three hooks (one top, two bottom) anchor the headgear to the cockroach’s hard head capsule, avoiding sensitive areas like compound eyes and mouthparts. This design lets the insect eat normally and keeps the device stable during movement. Instead of implanting electrodes into small, mobile cerci, the team focused on the second and sixth abdominal segments—rigid, stable areas with overlapping exoskeletons. The abdominal buckle includes: (1) U-shaped clamp: Fits the natural contour of the abdomen, securing the device vertically; (2) Gripping hooks: Clamp onto the edges of abdominal terga (exoskeletal plates), preventing slipping; (3) Overlapping structure integration: Leverages the insect’s natural segment overlap to enhance stability, allowing the abdomen to flex and extend freely during locomotion.
“To create these intricate, functional devices, we used digital light processing (DLP)-based multimaterial 3D printing and selective electroless copper plating—technologies that enable precise control over conductive and nonconductive regions.” emphasized the authors. The researchers tested their devices on Madagascar hissing cockroaches (Gromphadorhina portentosa)—a common cyborg model due to its 15g load-bearing capacity. Key results include stable neural responses, precise motion control, accurate S-Path navigation, and superior obstacle negotiation.
“The noninvasive design preserves the insect’s natural sensory capabilities, which is game-changing for real-world use,” said Hirotaka Sato, corresponding author and professor at NTU’s School of Mechanical and Aerospace Engineering. “This work moves cyborg insects from lab demonstrations to scalable, practical tools in robotics and biohybrid systems.”
Authors of the paper include Phuoc Thanh Tran-Ngoc, Kewei Song, Thu Ha Tran, Kazuki Kai, Qifeng Lin, and Hirotaka Sato.
This work was supported by the KLASS Engineering & Solutions Pte. Ltd. (RCA_Klass_REQ0374521) and NTUitive Pte. Ltd. (NGF-2022-11-020).
The paper, “Ergonomic Insect Headgear and Abdominal Buckle with Surface Stimulators Manufactured via Multimaterial 3D Printing: Snap-and-Secure Installation of Noninvasive Sensory Stimulators for Cyborg Insects” was published in the journal Cyborg and Bionic Systems on Sep 22, 2025, at DOI: 10.34133/cbsystems.0406.
Journal
Cyborg and Bionic Systems