Pressure sensors are widely used across engineering sectors, from monitoring load transfer in structural assemblies to ensuring uniform consolidation pressures during composite manufacturing. As composite systems increasingly move toward intelligent and multifunctional capabilities, there is a growing need for sensing approaches that are lightweight, flexible, and compatible with fibrous material architectures. Conventional electronic pressure sensors are often rigid or difficult to integrate within nonwoven and textile-based composite systems. This work presents advances in transforming commercially available nonwoven fabrics into multifunctional, sensing-enabled materials by coating them with carbon-based nanocomposites using a scalable, water-based electrophoretic deposition (EPD) process. Aqueous EPD of functionalized carbon nanotubes onto aramid, polyester, and glass nonwovens produces conformal, micrometer-scale porous nanocomposite coatings that impart electrical conductivity while preserving the inherent compliance and porosity of the fabric. Deposition parameters such as applied electric field, deposition time, and nanotube concentration are used to tune coating morphology and electromechanical response, with processing approaches demonstrated at batch and pilot scales and compatible with continuous textile manufacturing workflows. The resulting nonwoven sensors exhibit a broad and continuous pressure sensing response spanning tactile loads (<1 kPa), vacuum and contact pressures (~100 kPa), and high pressures on the order of tens of megapascals. This ultrawide sensing range arises from multiscale sensing.

Upper limb impairment significantly impacts daily activities and quality of life. Traditional robotic systems have been widely used in neurological rehabilitation applications. However, its adoption has been limited to laboratory and clinical settings due to cost constraints. Our study aimed to assess the feasibility and usability of a cost-effective virtual reality (VR) system for home-based upper limb training. We used a customized wearable sleeve sensor to assess the hand and elbow joint movements objectively. A pilot user study (n = 16) with healthy participants involved evaluating system usability, task load, and presence within two conditions of VR alone and VR combined with a customized inverse kinematics robot arm (KinArm). Results of statistical analysis using a two-way repeated measure (ANOVA) revealed no significant difference between conditions in task completion time. However, significant differences were observed in the normalized number of mistakes and recorded elbow joint angles between tasks. Our findings highlight the potential advantages of an immersive and multi-sensory approach towards performance assessment. This study explores avenues for the development of potentially cost-effective, tailored, and engaging environments for home-based therapy applications.

Physical therapy is often essential for complete recovery after injury. However, a significant population of patients fail to adhere to prescribed exercise regimens. Lack of motivation and inconsistent in-person visits to physical therapy are major contributing factors to suboptimal exercise adherence, slowing the recovery process. With the advancement of virtual reality (VR), researchers have developed remote virtual rehabilitation systems with sensors such as inertial measurement units. A functional garment with an integrated wearable sensor can also be used for real-time sensory feedback in VR-based therapeutic exercise and offers affordable remote rehabilitation to patients. Sensors integrated into wearable garments offer the potential for a quantitative range of motion measurements during VR rehabilitation. In this research, we developed and validated a carbon nanocomposite-coated knit fabric-based sensor worn on a compression sleeve that can be integrated with upper-extremity virtual rehabilitation systems. The sensor was created by coating a commercially available weft knitted fabric consisting of polyester, nylon, and elastane fibers. A thin carbon nanotube composite coating applied to the fibers makes the fabric electrically conductive and functions as a piezoresistive sensor. The nanocomposite sensor, which is soft to the touch and breathable, demonstrated high sensitivity to stretching deformations, with an average gauge factor of ~35 in the warp direction of the fabric sensor. Multiple tests are performed with a Kinarm end point robot to validate the sensor for repeatable response with a change in elbow joint angle. A task was also created in a VR environment and replicated by the Kinarm. The wearable sensor can measure the change in elbow angle with more than 90% accuracy while performing these tasks, and the sensor shows a proportional resistance change with varying joint angles while performing different exercises. The potential use of wearable sensors in at-home virtual therapy/exercise was demonstrated using a Meta Quest 2 VR system with a virtual exercise program to show the potential for at-home measurements.

Multiscale composites, where traditional fiber reinforcements are combined with nanoscale reinforcements, have emerged as multifunctional materials and have found potential for in situ strain and damage sensing, and energy harvesting/storage applications. Critical to the advancement of future applications is the development of manufacturing techniques that are industrially scalable. Electrophoretic deposition (EPD) can uniformly coat functionalized nanoparticles, such as carbon nanotubes (CNT), on conductive and non-conductive fiber substrates, producing multiscale composites with controlled microstructures and functional properties. In this research, a pilot-scale roll-to-roll EPD system is developed to continuously manufacture CNT-integrated fabrics for in situ sensing applications. Based on fundamental knowledge of CNT deposition mechanisms, key experiments are conducted to determine electrode configurations to optimize deposition yield in the roll-to-roll process. Functionalized CNTs are then deposited on 4-6 m long continuous rolls of randomly oriented non-woven glass fiber veil with different areal weights, and the CNTs form a continuous, conductive fiber-level coating. The thin and open fabric microstructure allows embedded sensors that are minimally invasive to the composite structure and allow ultraviolet (UV) light transmittance for use with UV-curable resins. The electrically conductive CNT network created on the fabric allows for the integration of sensing functionality. Short beam specimens with the CNT sensors embedded at the midplane showed no deterioration in strength. Multiple functionalities, including strain sensing and flow/UV cure monitoring during vacuum infusion are demonstrated. Sensors tested under flexural loading demonstrated sensitivity in tension and compression, and during resin infusion, the sensors could track resin flow and cure progression.

Carbon nanotube (CNT) addition to composite materials can offer both nanoscale reinforcement and a multifunctional element due to their extraordinary mechanical, thermal and electrical properties. Electrophoretic deposition (EPD) offers a scalable processing technique to incorporate CNTs into conventional fiber-reinforced polymer composites (FRPCs), facilitating the production of unique nanoscale structures in the critical interphase region. In this study, CNTs functionalized with polyethyleneimine (CNT-PEI) were deposited onto a planar substrate via EPD followed by the infusion of epoxy matrix in order to replicate the nanocomposite interphase region present in nanomodified FRPCs. The nanocomposite films have thicknesses ranging from several hundred nanometers to a few microns to represent different fiber-matrix interphase regions found in FRPCs. The morphology and mechanical performance of CNT-PEI/epoxy nanocomposites are examined using atomic force microscopy (AFM) in both tapping and nanoindentation modes. The EPD creates a homogeneously distributed porous CNT network bridged by PEI, forming the pathway of epoxy resin infusion through interconnected pores with diameters less than 100 nm. CNT-PEI/epoxy nanocomposites exhibited significant improvements in stiffness, hardness, and creep resistance compared to constituent porous CNT-PEI films and neat epoxy. The improvement was directly related to the ability of the load bearing CNTs chemically bonded with the epoxy matrix through the grafted PEI, providing an efficient load transfer mechanism. The chemical bond between the porous CNT-PEI and epoxy also produced far greater fracture surface in nanoscale scratch tests compared to unmodified epoxy, indicating the CNT-PEI/epoxy nanocomposite is capable of distributing load and absorbing more energy prior to fracture.

As the need for high-speed electronics continues to rise rapidly, printed wiring board (PWB) requirements become ever-more demanding. A typical PWB is fabricated by bonding dielectric films such as polyimide to electrically conductive copper foil such as rolled annealed (RA) copper and is expected to become thinner, flexible, durable, and compatible with high-frequency 5G performance. Polyimide films inherently feature a higher coefficient of thermal expansion (CTE) than copper foils; this mismatch causes residual thermal stresses. To attenuate the mismatch, silica nanoparticles may be used to reduce the CTE of PI. A nodulated copper surface can be used to enhance the Cu/PI adhesion by additional bonding mechanisms that could include a type of mechanical bonding, which is a focus of this study. In this investigation, a 90° peel test was used to measure the peel strength in copper/polyimide/copper laminates containing nodulated copper and polyimide reinforced with 0, 20, and 40 wt % silica nanoparticles. The influence of silica nanoparticles on the peel strength was quantitatively evaluated. Laminates incorporating polyimide films lacking silica nanoparticles had a ∼3.75× higher peel strength compared with laminates reinforced with 40% silica. Their failure surfaces were analyzed by using scanning electron microscopy (SEM), energy-dispersive X-ray analysis (EDX), and X-ray photoelectron spectroscopy to identify the mode of failure and to understand bonding mechanisms. The key bonding mechanism, mechanical interlocking, was achieved when the polyimide surrounded or engulfed the copper nodules when the laminate was created. Post-testing failure surface analysis revealed the presence of copper on the polyimide side and polyimide on the copper side, indicating mixed mode failure. An analytical model was developed to determine the impact of applied pressure, temperature, and time on the polyimide penetration and mechanical interlocking around the copper nodules. The model was validated by measuring the peel strength on another set of specimens fabricated using increased temperature and pressure that showed a 3× increase in peel strength compared to lower temperature/pressure processing conditions. This enhanced adhesion resulted from the lower polymer material viscosity at higher temperatures, which fosters deeper and more complete penetration around the copper nodules during processing at higher pressures for longer durations. The methodology of combining peel testing, viscosity and CTE measurement, SEM/EDX, surface chemical analysis, and penetration depth calculation developed herein enables the calculation of the desired processing parameters to enhance functionality and improve adhesion.

Electrophoretic deposition (EPD) using aqueous dispersions has been widely utilized to incorporate nanomaterials into fiber-reinforced composites to modify interfacial properties and introduce multifunctionality. The use of direct current EPD (DC EPD) allows deposition at a higher rate and with lower energy consumption but has limited ability to modify the intra-bundle regions of fabric substrates due to the side effects caused by vigorous water electrolysis, including gas evolution and high pH gradients that can destabilize the dispersion. Alternating current EPD (AC EPD), with sufficiently high frequency, is capable of suppressing the water electrolysis and altering the film formation mechanisms and morphology within the reinforcing fabric. In this research, an asymmetric triangular AC waveform with a zero net DC component is applied to EPD to achieve unique carbon nanotube (CNT) structures by controlling the thickness and distribution within the fabric structure. Distinctly different CNT morphologies are created by AC and DC EPD. The influence of porous electrodes on deposition kinetics and electrical conductivity is also investigated as the open pores provide the paths to dissipate evolved gas. The in-plane and through-thickness electrical conductivities of hierarchically structured CNT/glass/epoxy composite laminates are strongly affected by the as-deposited CNT morphology, as the CNTs are the only conductive constituent in the multiscale composite. AC EPD results in substantially increased CNT integration within the intra-bundle regions of the fibers. Multiscale composites fabricated by AC EPD combined with porous electrodes exhibit up to a 2300-fold increase in through-thickness electrical conductivity, while providing similar in-plane conductivity to DC EPD. The capability of tailoring the microstructure and through-thickness physical properties makes the multiscale nanocomposites fabricated by AC EPD promising for multifunctional applications such as anisotropic heat dissipation, de-icing, lightning strike protection, and in situ sensing of strain and damage.

Nanocomposites containing nanoscale materials offer exciting opportunities to encode nanoscale features into macroscale dimensions, which produces unprecedented impact in material design and application. However, conventional methods cannot process nanocomposites with a high particle loading, as well as nanocomposites with the ability to be tailored at multiple scales. A composite architected mesoscale process strategy that brings particle loading nanoscale materials combined with multiscale features including nanoscale manipulation, mesoscale architecture, and macroscale formation to create spatially programmed nanocomposites with high particle loading and multiscale tailorability is reported. The process features a low-shrinking (<10%) "green-to-brown" transformation, making a near-geometric replica of the 3D design to produce a "brown" part with full nanomaterials to allow further matrix infill. This demonstration includes additively manufactured carbon nanocomposites containing carbon nanotubes (CNTs) and thermoset epoxy, leading to multiscale CNTs tailorability, performance improvement, and 3D complex geometry feasibility. The process can produce nanomaterial-assembled architectures with 3D geometry and multiscale features and can incorporate a wide range of matrix materials, such as polymers, metals, and ceramics, to fabricate nanocomposites for new device structures and applications.

Due to their high specific strength, stiffness, and energy-absorbing properties, glass fiber epoxy composites are commonly used in automotive, aerospace, and other consumer applications. The Army uses these composites in ground vehicles for various structures, and they are often subjected to a wide range of environmental conditions, with varying temperature and moisture conditions. They may also be subjected to high strain rate loading. While the influence of environmental conditions on the properties of the reinforcing fibers is minimal, a fundamental understanding of its effect on the resin and interfacial adhesion is critical in evaluating the behavior of these composites. This research focuses on characterizing the effect of temperature and moisture on the interfacial bonding between S2 glass fibers (with 463 sizing) and epoxy resin using single fiber pullout testing. Epoxy resin SC-15, commonly used in these applications, is tested at room temperature, -55ºC and 76ºC. The range is chosen based on the operating temperature defined by MIL 810 standards. The embedded length is comparable for all tests, of the order of 55-60 μm. The embedded length and average diameter are measured using a scanning electron microscope image of the failed specimen to calculate the apparent IFSS. The IFSS shows a strong correlation with temperature; an increase in IFSS at -55ºC and a decrease at 76ºC. An 89% increase was measured at -55ºC and a 45% decrease at 76ºC when compared to room temperature tests. The IFSS measured is dependent on various factors such as the surface roughness of the fiber, chemical bonds between the resin and the fiber (sizing), and the residual compression forces that induce friction within debond regions due to the difference in CTE (coefficient of thermal expansion) between the fiber and the resin. Due to competing mechanisms of resin failure or interfacial failure, in some cases, a residue of the resin on the fiber may be present. A discussion of these mechanisms and a comparison with the resin properties at different temperatures is discussed.

This research focuses on the investigation of damage mechanisms induced through the processing and consolidation of UHMWPE composites (HB210). The HB210 composites consist of Dyneema® fibers and thermoplastic polyurethane resin. The composite panel consisting of 72 sheets was processed following the manufacturer’s recommended temperature and pressure profile of 100°C and 2 MPa (290 psi) for 10 minutes, followed by 125°C and 20.7MPa (3ksi) for 30 minutes. Each sheet consists of 0/90/0/90 ply orientation with an average sheet thickness of 200 μm. To quantify the effects of consolidation pressure on fiber deformation and tensile strength distribution, a technique for extracting fibers from the processed panels was developed. Specimens (11 x 19 x 152 mm) were cut from the panel and immersed in tetrahydrafuran (THF) fluid for 7-20 days (dependent on the specimen thickness). The THF effectively dissolved the matrix enabling UHMWPE fibers to be extracted at different locations through the thickness. The baseline tensile strength distribution was based on testing virgin fibers from the spool and fibers extracted using the THF method from a single as-received layer of HB210. The two baselines exhibited statistically equivalent tensile strength distributions proving the THF extraction method did not affect the fiber properties and that degradation of tensile strength is a result of the consolidation process. From tensile test data, strength distributions for extracted fibers from consolidated panel were generated, and strength at 50% failure probability was evaluated. Compared to the baseline, the fibers extracted from the processed panel showed a 15% reduction in the average tensile strength. SEM microscopy of the extracted fibers from the consolidated panel exhibits different damage modes. Surface cracking and flattening damage modes were induced by the consolidation pressure (20.7 MPa) applied in the thickness direction of the panel. Additionally, axial kinking was observed along the length of the fibers. The possible mechanisms for the formation of these kinks are – viscous forces from the resin during the consolidation process, where fibers loaded in compression are observed to kink into large voids between fibers, or due to the CTE mismatch between the fibers and the resin within a layer or between the 0 and 90 layers within a sheet during the cooling stage.

Abstract This study presents a new wearable insole pressure sensor (IPS), composed of fabric coated in a carbon nanotube-based composite thin film, and validates its use for quantifying ground reaction forces (GRFs) during human walking. Healthy young adults (n = 7) walked on a treadmill at three different speeds while data were recorded simultaneously from the IPS and a force plate (FP). The IPS was compared against the FP by evaluating differences between the two instruments under two different assessments: (1) comparing the two peak forces at weight acceptance and push-off (2PK) and (2) comparing the absolute maximum (MAX) of each gait cycle. Agreement between the two systems was evaluated using the Bland–Altman method. For the 2PK assessment, the group mean of differences (MoD) was −1.3 ± 4.3% body weight (BW) and the distance between the MoD and the limits of agreement (2S) was 25.4 ± 11.1% BW. For the MAX assessment, the average MoD across subjects was 1.9 ± 3.0% BW, and 2S was 15.8 ± 9.3% BW. The results of this study show that this sensor technology can be used to obtain accurate measurements of peak walking forces with a basic calibration and consequently open new opportunities to monitor GRF outside of the laboratory.

Stroke patients often experience upper limb impairments that restrict their mobility and daily activities. Physical therapy (PT) is the most effective method to improve impairments, but low patient adherence and participation in PT exercises pose significant challenges. To overcome these barriers, a combination of virtual reality (VR) and robotics in PT is promising. However, few systems effectively integrate VR with robotics, especially for upper limb rehabilitation. This work introduces a new virtual rehabilitation solution that combines VR with robotics and a wearable sensor to analyze elbow joint movements. The framework also enhances the capabilities of a traditional robotic device (KinArm) used for motor dysfunction assessment and rehabilitation. A pilot user study (n = 16) was conducted to evaluate the effectiveness and usability of the proposed VR framework. We used a two-way repeated measures experimental design where participants performed two tasks (Circle and Diamond) with two conditions (VR and VR KinArm). We observed no significant differences in the main effect of conditions for task completion time. However, there were significant differences in both the normalized number of mistakes and recorded elbow joint angles (captured as resistance change values from the wearable sleeve sensor) between the Circle and Diamond tasks. Additionally, we report the system usability, task load, and presence in the proposed VR framework. This system demonstrates the potential advantages of an immersive, multi-sensory approach and provides future avenues for research in developing more cost-effective, tailored, and personalized upper limb solutions for home therapy applications.

S-2 glass-epoxy composites are used in damage tolerant structural applications such as military ground vehicles due to their high specific strength, stiffness, and energy-absorbing capabilities. Composites can be susceptible to delamination failure caused due to high interlaminar shear stresses when subjected to transverse impact loading. While fiber fracture, fiber pullout, matrix cracking, and delaminations are the major damage mechanisms, delamination is a significant energy absorbing failure mode in low-velocity impacts (LVI). LVI leads to a reduction of stiffness and residual strength, which is critical for structural integrity. To improve the delamination resistance, researchers have used various types of interlayers for composites subjected to impacts. In this research, LVI experiments are conducted on composites made using plain weave S-2 glass and SC-15 epoxy resin. Two types of specimens are tested, 'baseline' (without interlayer) and 'interlayer' (with thermoplastic interlayer UAF 472). A Dynatup 9200 drop tower with a hemi-cylindrical 12.7 mm impactor is used. The specimens are impacted (40J) at three temperatures, -55C, RT, and 76C. The stiffness before and after the LVI test is evaluated, and the influence of temperature and impacts on stiffness change is discussed, along with the mechanisms that cause the change in stiffness. The interlayer specimens have significantly smaller delamination areas, and the stiffness loss due to impact is also reduced (compared to baseline) at each temperature. However, since the properties of the resin and the TPU deteriorate at elevated temperatures, there is a drastic stiffness loss in interlayer specimens at elevated temperatures in the pristine, non-impacted samples.

Functionalized carbon nanotubes are deposited using an aqueous electrophoretic deposition process on everyday fabrics to create flexible wearable sensors, with ultrahigh sensitivity to detect human movements, from arm flexing to finger bending.

Electrophoretic deposition is a promising technique to hybridize nanomaterials with conventional reinforcing materials for multifunctional applications. It utilizes the principle of electrophoresis, where electric potential drives charged particles dispersed in a liquid towards counter-charged substrates. Polymer matrix can be infused into the hybridized fibers to produce hierarchical polymer composites with reinforcements spanning several orders of magnitude in scale. This research addresses a key challenge associated with nanostructured composites produced by first dispersing the nanoscale reinforcement into the polymer matrix and then infusing into the fiber reinforcement (direct mix/infusion method). The key limitation is on the volume fraction of the nanoscale particles due to the drastic increase of the resin viscosity and the potential filtering effect of the particles during resin infusion. Our model system consists of an aqueous dispersion of carbon nanotubes (CNT) functionalized with a cationic polymer, polyethyleneimine (PEI), non-conductive glass fabric and epoxy resin. Amine functional groups of PEI are protonated under mildly acidic conditions, producing positively charged CNTs. A stable dispersion is formed through repulsive electrostatic forces among charged CNTs, which also facilitates deposition under applied electric fields. CNT-PEI films uniformly deposited via EPD on each filament throughout the fabric form a unique interface between reinforcing fiber and epoxy matrix. Concentrated amines from CNT-PEI coatings possibly alter the curing mechanism of infused epoxy resin, thereby creating the graded mechanical properties at the interface. In this study, curing kinetics and thermomechanical properties of epoxy resin are investigated with added PEI which provides stoichiometrically excessive amines. It is expected that the curing temperature profile can be designed to optimize the interfacial properties of electrophoretically processed CNT-PEI multiscale composites.

Carbon nanotube (CNT) composite films are deposited onto stretchable knit fabrics using electrophoretic deposition (EPD) and dip-coating techniques, which are industrially scalable processes for producing future wearable sensors. The deposited CNTs create an electrically conductive nanocomposite film on the surface of the fibers. These nanocomposite coated fabrics exhibit piezoresistive properties; under mechanical deformation/stretching, a large change in the electrical resistance is observed. Polyethyleneimine (PEI) functionalized carbon nanotubes deposited using EPD create a uniform, extremely thin porous coating on the fiber. Initial results show ultrahigh sensitivity of the carbon nanotube coated fabric when tested on elbow/knee to detect range of motion. The sensitivity of these sensors is exceptionally high when compared to a typical carbon nanotube-based polymer nanocomposite. The nanocomposite coating does not affect fabric's breathability or flexibility, making the sensor comfortable to wear. Because of these unique properties, tremendous potential exists for their use in functional/smart garments. Changes in electrical resistance for these fabrics are influenced by a combination of electron tunneling between the carbon nanotubes and the microstructure of the fabric. To investigate and characterize the unique sensing mechanism, the nanotube coated knit fabric's electromechanical response is studied at different length scales, from individual yarns to fabric levels. For applications in wearable sensors, the durability of the nanotube coating on the fabric is critical for repeatable and reliable sensing response. Durability testing of the sensing fabric for washing loads was conducted to study the nanotube coating's robustness. CNT coating's adhesion quality is evaluated based on the weight loss in the specimen and loss in electrical conductivity in each wash cycle. This research addresses the potential of these sensors for functional/smart garments by examining the underlying mechanism of the sensor response and the durability of the carbon nanotube coating.

Boron nitride nanotubes (BNNTs) represent a relatively new class of materials that provides alternative electrical and thermal properties to the carbon analogue. The high chemical and thermal stability and large band gap combined with high electrical resistance make BNNTs desirable in several thin-film applications. In this study, stable BNNT and hexagonal boron nitride (hBN) particle dispersions have been developed using environmentally friendly advanced oxidation processing (AOP) that can be further modified for electrophoretic deposition (EPD) to produce thin films. The characterization of the dispersions has revealed how the hydroxyl radicals produced in AOP react with BNNT/hBN and contaminant boron nanoparticles (BNPs). While the radicals remove the carbon contaminant present on BNNT/hBN and increase dispersion stability, they also oxidize the BNPs and the boron oxide produced, which, conversely, reduces the dispersion stability. The use of high- or low-powered ultrasonication in combination with the AOP affects the rate of the competing reactions, with low-powered sonication and AOP providing the best combination for producing stable dispersions with high concentrations. BNNT/hBN dispersions were functionalized with polyethyleneimine to facilitate EPD, where films of several micrometer thickness were readily deposited onto stainless steel and glass-fiber fabrics. BNNT/hBN films produced on glass fabrics by EPD exhibited a consistent through-thickness macroporosity that was facilitated by platelet and nanotube stacking. The film macroporosity present on the coated fabrics was suitable for use as separator layers in supercapacitors and provided improved device robustness with a minimal impact on electrochemical performance.

We introduce Robot DE NIRO, an autonomous, collaborative, humanoid robot for mobile manipulation. We built DE NIRO to perform a wide variety of manipulation behaviors, with a focus on pick-and-place tasks. DE NIRO is designed to be used in a domestic environment, especially in support of caregivers working with the elderly. Given this design focus, DE NIRO can interact naturally, reliably, and safely with humans, autonomously navigate through environments on command, intelligently retrieve or move target objects, and avoid collisions efficiently. We describe DE NIRO's hardware and software, including an extensive vision sensor suite of 2D and 3D LIDARs, a depth camera, and a 360-degree camera rig; two types of custom grippers; and a custom-built exoskeleton called DE VITO. We demonstrate DE NIRO's manipulation capabilities in three illustrative challenges: First, we have DE NIRO perform a fetch-an-object challenge. Next, we add more cognition to DE NIRO's object recognition and grasping abilities, confronting it with small objects of unknown shape. Finally, we extend DE NIRO's capabilities into dual-arm manipulation of larger objects. We put particular emphasis on the features that enable DE NIRO to interact safely and naturally with humans. Our contribution is in sharing how a humanoid robot with complex capabilities can be designed and built quickly with off-the-shelf hardware and open-source software. Supplementary Material including our code, a documentation, videos and the CAD models of several hardware parts are openly available at https://www.imperial.ac.uk/robot-intelligence/software/.