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Additively Manufactured Dielectric Elastomer Actuators: Development and Performance Enhancement

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Additively Manufactured Dielectric Elastomer Actuators: Development and Performance Enhancement PhD Dissertations and Master's Theses 7-2021 Additively Manufactured Dielectric Elastomer Actuators: Development and Performance Enhancement Stanislav Sikulskyi Follow this and additional works at: https://commons.erau.edu/edt Part of the Aerospace Engineering Commons This Dissertation - Open Access is brought to you for free and open access by Scholarly Commons. It has been accepted for inclusion in PhD Dissertations and Master's Theses by an authorized administrator of Scholarly Commons. For more information, please contact [email protected]. ADDITIVELY MANUFACTURED DIELECTRIC ELASTOMER ACTUATORS: DEVELOPMENT AND PERFORMANCE ENHANCEMENT By Stanislav Sikulskyi A Dissertation Submitted to the Faculty of Embry-Riddle Aeronautical University In Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy in Aerospace Engineering July 2021 Embry-Riddle Aeronautical University Daytona Beach, Florida ii ADDITIVELY MANUFACTURED DIELECTRIC ELASTOMER ACTUATORS: DEVELOPMENT AND PERFORMANCE ENHANCEMENT By Stanislav Sikulskyi This Dissertation was prepared under the direction of the candidate’s Dissertation Committee Chair, Dr. Daewon Kim, Department of Aerospace Engineering, and has been approved by the members of the Dissertation Committee. It was submitted to the Office of the Senior Vice President for Academic Affairs and Provost, and was accepted in the partial fulfillment of the requirements for the Degree of Philosophy in Aerospace Engineering. DISSERTATION COMMITTEE Digitally signed by Marwan Al-Haik Digitally signed by Daewon Kim DN: cn=Marwan Al-Haik, o=Embry-Riddle Date: 2021.08.04 12:05:57 Aeronautical University, ou=Aerospace Daewon Kim Marwan Al-Haik Engineering, [email protected], c=US -04'00' Date: 2021.08.04 21:19:27 -04'00' Chairman, Dr. Daewon Kim Member, Dr. Marwan Al-Haik Digitally signed by Mandar D. Digitally signed by Sirish Namilae Mandar D. Kulkarni Sirish Namilae Date: 2021.08.04 13:55:38 -04'00' Kulkarni Date: 2021.08.04 15:09:16 -04'00' Member, Dr. Sirish Namilae Member, Dr. Mandar Kulkarni Digitally signed by Eduardo A. Digitally signed by Foram Madiyar Rojas Eduardo A. Rojas Foram Madiyar Date: 2021.08.04 15:32:46 -04'00' Date: 2021.08.04 12:32:10 -04'00' Member, Dr. Eduardo Rojas Member, Dr. Foram Madiyar Digitally signed by Sirish Namilae Sirish Namilae Date: 2021.08.05 09:54:06 -04'00' 08/05/2021 Graduate Program Coordinator, Date Dr. Sirish Namilae Digitally signed by Maj Mirmirani Maj Mirmirani Date: 2021.08.05 12:22:29 -04'00' 08/05/2021 Dean of the College of Engineering, Date Dr. Maj Mirmirani Digitally signed by Lon Moeller Date: 2021.08.05 13:17:11 Lon Moeller -04'00' 08/05/2021 Senior Vice President for Academic Date Affairs and Provost Lon Moeller, J.D. iii ACKNOWLEDGEMENTS First and foremost, I would like to express my sincere appreciation to my advisor Dr. Daewon Kim for introducing me to the field of Smart Materials, giving the opportunity to do research, and supporting me enormously in pursuing the degree of Doctor of Philosophy in Aerospace Engineering. I recognize the committee members, Dr. Marwan Al-Haik, Dr. Sirish Namilae, Dr. Mandar Kulkarni, Dr. Eduardo Rojas, and Dr. Foram Madiyar, for their suggestions for improving the research. Particular thanks to Dr. Eduardo Rojas for providing and teaching essential equipment and skills and to Dr. Foram Madiyar for help in material selection and processing. I also would like to acknowledge Embry-Riddle Aeronautical University for becoming the second home while providing high-quality education, research facilities, equipment, and the great experience of teaching. I am grateful to my friends and colleagues, Danayit Mekonnen, Rishikesh Govindarajan, Taylor Stark, Aryslan Malik, Mergen Alimaganbetov, Yevgeniy Lischuk, Andrew Matievski and others, for enjoyable time doing research together, their help and shared experience, and just for fun time. Finally, I am incredibly grateful to my parents, my wife, all my family and friends for their support over these years. iv ABSTRACT The recently emerging and actively growing areas of soft robotics and morphing structures promise endless opportunities in a wide range of engineering fields, including biomedical, industrial, and aerospace. Soft actuators and sensors are essential components of any soft robot or morphing structure. Among the utilized materials, dielectric elastomers (DEs) are intrinsically compliant, high energy density polymers with fast and reversible electromechanical response. Additionally, the electrically driven work principle allows DEs to be distributed in a desired fashion and function locally with minimum interference. Thus, a great effort is being made towards utilizing additive manufacturing (AM) technologies to fully realize the potential of DE soft actuators and sensors. While soft sensors have received more attention and development due to their simpler implementation, DE actuators (DEAs) set stricter AM and electrode material requirements. DEAs’ layered structure, compliant nature, and susceptibility to various defects make their manufacturability challenging, especially for non-trivial biomimetic soft robotics geometries. This dissertation comprehensively analyzes DE materials’ transition into a soft actuator using AM to facilitate effective DEA soft actuator fabrication. Closely interrelated fabrication techniques, material properties, and DEA geometries are analyzed to establish a fundamental understanding of how to implement high-quality DEA soft actuators. Furthermore, great attention is paid to enhancing the performance of printed DEAs through developing printable elastomer and electrode materials with improved properties. Lastly, performance enhancement is approached from the design point of view by developing a novel 3D printable DEA configuration that actuates out-of-plane without stiffening elements. v TABLE OF CONTENTS ACKNOWLEDGEMENTS ........................................................................................... iii ABSTRACT. .................................................................................................................. iv LIST OF FIGURES ....................................................................................................... viii LIST OF TABLES ......................................................................................................... xiv ABBREVIATIONS ....................................................................................................... xv 1. Introduction ................................................................................................................ 1 1.1. Motivation ......................................................................................................... 1 1.1.1. Materials .................................................................................................. 2 1.1.2. Manufacturing .......................................................................................... 3 1.1.3. Design ...................................................................................................... 4 1.1.4. Modeling .................................................................................................. 4 1.2. Objectives ......................................................................................................... 5 2. Review of the Relevant Literature ............................................................................. 7 2.1. DEA Smart Material ......................................................................................... 7 2.2. DEA Configurations ......................................................................................... 10 2.3. DEA Modeling .................................................................................................. 13 2.3.1. General DEA Modeling ........................................................................... 13 2.3.2. Unimorph and Bimorph DEAs ................................................................ 17 2.4. Dielectric Elastomer (DE)................................................................................. 19 2.4.1. DE Material Selection .............................................................................. 21 2.5. DEA Electrodes ................................................................................................ 22 2.6. Manufacturing ................................................................................................... 29 2.6.1. Conventional Methods ............................................................................. 29 2.6.2. AM Methods ............................................................................................ 31 2.6.3. Partially Printed DEAs ............................................................................. 39 2.6.4. Fully Printed DEAs .................................................................................. 41 2.6.5. Summary of AM Methods for 3D Printed DEAs .................................... 50 2.7. Methodology ..................................................................................................... 51 3. AM of DEAs .............................................................................................................. 53 3.1. AM Considerations for DEAs ........................................................................... 53 3.1.1. Materials .................................................................................................. 54 3.1.2. Substrates ................................................................................................
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