Scientists use AI-powered robots to assemble cyborg insects for use in search and rescue and rescue operations

Scientists from Singapore (NTU Singapore) have built the world's first automated cyborg insect, the Factory Line. This new prototype robot system automates the installation of a miniature electronic backpack on the back of a cockroach called Madagascar Shoe, transforming it into a hybrid insect robot.

This new assembly method significantly reduces preparation time and human error, and takes a major step towards the massive deployment of insect hybrid robots in complex environments for search and rescue efforts in disaster zones.

This study is published in the journal Natural Communication.

The automated system, led by Professor Sato of the Department of Mechanical and Aerospace Engineering at NTU Singapore, allows you to attach an electronic “backpack” to a cockroach that hedges a Madagascar “backpack” in just 1 minute and 8 seconds per insect.

This is about 60 times faster than traditional manual processes that rely on trained operators, and often takes over an hour. After treating the four insects, the system completed all assembly within 8 minutes. This is about 30 times faster than the manual method.

“Our innovation makes the dream of deploying a large number of cyborg insects in real-life scenarios much more practical,” Professor Sato said.

“Manual preparation is time-consuming and highly dependent on skilled operators. By automating the process, hybrid insect robots can be produced quickly and consistently, making it important for time-sensitive operations such as search and rescue after a disaster.”

If the cockroach is no longer deployed or during a long break, the miniature electronic backpack can be safely removed from the back without any adverse effects.

How Cyborg Insects Work

Unlike traditional robots, cyborg insects are usually moved using their limbs and are guided by gentle electrical stimulation provided through embedded electrodes connected to the lightweight circuit board on their back.

AI-enabled robot assembly systems use computer vision and proprietary algorithms to identify the optimal anatomical site on the cockroach's back for electrode implantation, ensuring accurate placement.

The researchers also designed a new generation of backpacks that stimulate insects more efficiently, using 25% less voltage than previous versions, while maintaining precise control of movement. This additional power efficiency helps to extend operational time and reduce the risk of overstimulation.

On clinical testing, the hybrid insects showed sudden turns above 70 degrees, with speeds of up to 68%.

A pack of four cyborg cockroaches covered over 80% of the obstacle-filled test area in just 10.5 minutes, demonstrating the ability to navigate tight, messy spaces.

The assembly line is still in the prototype stage, but cyborg insects with first-generation backpacks installed using manual methods are already seeing actual use.

Real World Applications

On March 30, 2025, a team of 10 cyborg insects was deployed to Myanmar along with the Singapore Civil Defense Force (SCDF) as part of the Lionheart Incident.

The humanitarian mission is in response to the devastating 7.7 magnitude earthquake struck on March 28, claiming more than 3,000 lives.

This was the first time a cyborg insect was used in the first field deployment of humanitarian operations and insect hybrid robots.

Field deployment demonstrated the potential of insect-based robotics to find survivors in disaster-hit regions where traditional robots struggled with access and short operational times.

“Learning from our field deployments is essential to create an infrastructure that supports mass production and deployment,” says Professor Sato. “We believe our assembly line is the first step towards that goal and will pave the way for more reliable cyborg applications, including inspection of large-scale civic structures for defects.”

Professor Sato is internationally recognized for his pioneering work in cyborg insects. His groundbreaking research is featured in time The magazine's “50 Best Inventions of the Year” MIT Technology Review “10 Emerging Technologies.”

Going forward, his team aims to improve the assembly system and work with local partners to further verify the effectiveness and preparation of the industrial use.