When they design mechanical systems, engineers first need to understand how they will behave using mathematical modelling tools that can simulate their movements. In recent years, they have increasingly explored the possibilities of ‘compliant’ mechanisms: highly flexible systems which are now being applied across numerous leading fields of technology. However, because their motions are often incredibly complex, engineers have so far found it difficult to recreate their behaviours in the mathematical tools needed to design them. Because they involve complex, nonlinear behaviour, designing compliant mechanisms has posed a long-standing challenge for engineers. While several advanced synthesis methods are now available, they’re often computationally intensive and can’t readily cope with the inevitable uncertainties in a system’s operating variables. In their latest research, Ahmed Alhindi and Dr. Meng-Sang Chew at Lehigh University, Pennsylvania, propose a novel approach that directly accounts for uncertainty in the design process. By reformulating widely used equations, their ‘dimensional synthesis’ method offers a streamlined yet powerful way to design compliant mechanisms under real-world, uncertain conditions.