Fabricating multi-component skin systems for robotics and other applications

A computer-based method for fabricating an object with an exterior skin, comprising:

• storing in memory a 3D base geometry model defining surface geometry of the object and a model of an inner support structure, wherein the inner support structure comprises a structural shell;
• fabricating the inner support structure including the structural shell based on the inner support structure model;
• fabricating an exterior skin mold based on the 3D base geometry model;
• and
• forming the exterior skin over the inner support structure by positioning the inner support structure in the exterior skin mold and filling the exterior skin mold with one or more materials,
• wherein the inner support structure further comprises an inner skin component positioned on an exterior surface of the structural shell.

A method of fabricating an object covered with a multi-hardness skin system, comprising:

• creating a 3D computer model defining surface geometry of the object;
• modeling an inner support structure for the object based on the 3D computer model of the object, the inner support structure model comprising a structural shell and a backing component on an exterior surface of the structural shell;
• fabricating the inner support structure including molding the backing component with an outer surface using a mold fabricated based on the inner support structure model, the molded backing component comprising an elastic material with a first hardness;
• fabricating an exterior skin mold for the object based on the 3D computer model of the object;
• positioning the fabricated inner support structure within the exterior component mold;
• and
• filling the exterior skin mold with a material.