Robot-assisted feeding systems enhance the independence of individuals with motor impairments and alleviate caregiver burden. While existing systems predominantly rely on software-based safety features to mitigate risks during unforeseen collisions, this study explores the use of a mechanical fail-safe to improve safety. We designed a breakaway utensil attachment that decouples forces exerted by the robot on the user when excessive forces occur. Finite element analysis (FEA) simulations were performed to predict failure points under various loading conditions, followed by experimental validation using 3D-printed attachments with variations in slot depth and wall loops. To facilitate testing, a drop test rig was developed and validated. Our results demonstrated a consistent failure point at the slot of the attachment, with a slot depth of 1 mm and three wall loops achieving failure at the target force of 65 N. Additionally, the parameters can be tailored to customize the breakaway force based on user-specific factors, such as comfort and pain tolerance. CAD files and utensil assembly instructions can be found here:this https URL
View on arXiv@article{chang2025_2502.17774,
title={ Design of a Breakaway Utensil Attachment for Enhanced Safety in Robot-Assisted Feeding },
author={ Hau Wen Chang and J-Anne Yow and Lek Syn Lim and Wei Tech Ang },
journal={arXiv preprint arXiv:2502.17774},
year={ 2025 }
}