A Systematic Approach for Designing Slender Continuum Robots for Extended-Reach Aeroengine Endoscopic Applications

Borescope inspection is essential for assessing the airworthiness of aircraft gas turbines. Yet, current procedures remain highly manual, operator-dependent, and inconsistent, which limits the reliability of subsequent image-based damage analysis. This paper introduces a systematic design approach for an ultra-slender continuum robot (CR) tailored to the geometric and operational constraints of aero-engine inspection. We formalize the design space, compare actuation concepts, and select a tendon-driven architecture based on a structured evaluation. Dimensional synthesis is formulated as an optimization problem that maximizes the visible blade surface, yielding segment lengths that ensure high inspection coverage. We detail design, material, and cable choices, the actuation unit, and two variants of the manipulator: A fully actuated (FA) version and a hybrid version with a passive carrier (PC). Evaluation in a high-pressure compressor mock-up reveals distinct strengths in stiffness, controllability, friction, pose observability, and system complexity between the two systems. Based on these findings, future work should focus on advancing a hybrid solution that combines the benefits of both approaches. Moreover, the presented methodology is not limited to high-pressure compressor inspection but can be applied to any section of the engine, significantly broadening its scope of application.