Single-process 3D-printed stacked dielectric actuator

Single-process additive manufacturing provides fully functional 3D-printed structures in a single 3D printer without the need for additional manufacturing processes. The 3D-printed parts can be scaled, individualized, embedded, and combined into multi-functional structures without modifications to the fabrication technology.This manuscript reports the first demonstration of monolithically 3D-printed stacked dielectric actuators (SDEAs) in a single fabrication process utilizing a commercially accessible extrusion 3D printer and thermo-plastic filaments. Neither single-layer nor stacked dielectric actuators have been 3D printed with thermoplastic filament extrusion in a single process until now.To achieve single-process fabrication, this research successfully addresses the main challenges: single-process fabrication of the dielectric layer and electrodes, repeatability and reliability of the 3D-printed thin dielectric layer, and layer stacking.Four actuators with different active areas and a number of stacked active layers were 3D printed. The functionality of the 3D-printed actuators was demonstrated with dynamic electromechanical characterization in a free-displacement and blocked-force configuration in a broad frequency range (up to 5 kHz).The actuators show promise for applications that require high-frequency resonators or high controllability in the sub-resonance region.

Automated summary

This research demonstrates the first monolithic 3D-printed stacked dielectric actuators (SDEAs) using a commercially accessible extrusion 3D printer and thermoplastic filaments. The challenges of single-process fabrication of the dielectric layer and electrodes, repeatability and reliability of the 3D-printed thin dielectric layer, and layer stacking were successfully addressed. Four actuators with different active areas and stacked active layers were 3D printed and their functionality was demonstrated through dynamic electromechanical characterization. These actuators show promise for applications requiring high-frequency resonators or high controllability in the sub-resonance region.