Architecture for the semi-automatic fabrication and assembly of thin-film based dielectric elastomer actuators. M. Randazzo 1a , R. Buzio b , G. Metta a , G. Sandini a and U. Valbusa b a Italian Institute of Technology, Via Morego 30, 16163, Genova, Italy and Department of Communication Computer and System Sciences, University of Genova,Viale Francesco Causa 13, 16145, Genova, Italy b Nanomed Labs, Advanced Biotechnology Center, Largo R. Benzi 10, 16132 Genova and Physics Department, University of Genova, Via Dodecaneso 33, 16146 Genova, Italy ABSTRACT One problem related to the actuation principle of macroscopic dielectric elastomer actuators is the high voltage required, typically in the Kilovolt range, that imposes particular care in the insulation of the whole actuator from the surrounding environment. This high actuation voltage, however, can be drastically reduced if a thin film of dielectric elastomer is used. Despite this, the manufacture of a macroscopic stack-like actuator, starting from thin films of dielectric elastomer can present many manufacture difficulties, like the handling and the assembly of the films, the power distribution to hundreds or thousands of layers, the presence of defects in one single layer that can cause the complete failure of the whole actuator. In this paper, a fast, semi-automatic process is proposed for the manufacture of modular units of dielectric elastomer, each of them consisting of many layers of rolled thin dielectric film. All the manufactured units are independent and take their power from a lateral, compliant supply rail that contacts the sides the electroded layers. This design is very suitable for industrial production: each module can be independently tested and then assembled in a complete macroscopic actuator composed by an unlimited number of these modules. The simple assembly methodology and the semi-automatic manufacture process described in this paper allows the fabrication of multilayer stacked devices, that can be used both as contractile or expanding actuators. Keywords: Multilayer dielectric elastomer actuators, thin-films, semi-automatic fabrication procedure 1. INTRODUCTION Electroactive Polymers (EAPs) are polymers able to respond to electrical stimulations, modifying their shape when an external voltage is applied to them[1][2]. For this reason, EAPs are also often called “artificial muscles” because, even if they don’t share the same operative principle of biological muscles, their functional response is similar, and they have characteristics of generated stress and strain approaching the capabilities of the mammalian muscles. These peculiar characteristics of EAPs make them extremely attractive for the study of novel actuation mechanisms, and it is expected that their continuous improvement in terms of performance and reliability will open new perspectives to fields like prosthetics, robotics, telepresence, rehabilitation etc. Dielectric Elastomer Actuators (DEA)[3][4] represents one class of electroactive polymers that have already demonstrated good performances and offer great potentials for mechatronic and robotic applications, especially in the field of biomimetic mechanisms and humanoid robotics. DEAs are in fact superior in terms of lightness and energy efficiency to traditional electromagnetic actuators and own an intrinsic softness that makes their use advantageous when a safe, compliant interaction with the surrounding environment is required. Compared to many other EAPs, moreover, 1 E-mail: marco.randazzo@unige.it; phone +39 010 71781; fax +39 010 353 2144;