Abstract In this paper, we form a constrained optimization problem for spherical four-bar motion generation. Instead of using local optimization methods, all critical points are found using homotopy continuation solvers. The complete solution set provides a full view of the optimization landscape and gives the designer more freedom in selecting a mechanism. The motion generation problem admits 61 critical points, of which two must be selected for each four-bar mechanism. We sort solutions by objective value and perform a second order analysis to determine if the solution is a minimum, maximum, or saddle point. We apply our approximate synthesis technique to two applications: a hummingbird wing mechanism and a sea turtle flipper gait. Suitable mechanisms were selected from the respective solution sets and used to build physical prototypes.
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