The development of intelligent and adaptive mechanical systems has sparked growing interest in smart material-driven compliant structures. Shape memory alloy (SMA) wires show particular promise due to their high load-to-weight ratio, flexibility, and controllable actuation characteristics. However, current research lacks systematic methodologies for developing SMA wire-driven compliant components and integrating them into functional mechanisms. This thesis aims to establish comprehensive approaches for the design, parametric modeling, synthesis, and fabrication of SMA wire-driven active compliant components and mechanisms.
SMA wire-driven active compliant components were systematically investigated through material characterization, manufacturing process development, and parametric studies. Different component configurations were designed and tested to investigate the influence of key design parameters on deformation behavior, successfully achieving both planar and spatial (2.5D) deformations. The integration of sensing capabilities into the component was demonstrated, enabling closed-loop control of deformation. Parametric analytical models were developed to predict component deformation behavior under various loading conditions. Deformation similarity relationships for components with different dimensions were derived. Based on similarity transformation principles, a synthesis methodology for SMA wire-driven compliant mechanisms was established for motion generation tasks, with experimental validation through prototype development of both open-chain and closed-chain compliant mechanisms. This thesis contributes fundamental design and manufacturing guidelines, as well as analysis and synthesis tools for SMA wire driven components and mechanisms.