Batch‐Sprayed and Stamp‐Transferred Electrodes: A New Paradigm for Scalable Fabrication of Multilayer Dielectric Elastomer Actuators

Abstract Multilayer dielectric elastomer actuators have a wide range of potential applications, but their development and commercial implementation been hindered by existing manufacturing processes. Existing processes are low‐throughput, limited in area, and/or can only process narrow elastomers. This study presents novel fabrication paradigm that overcomes these challenges: instead sequentially patterning electrodes directly onto successive layers, electrode stamps patterned carrier film an independent batch‐spray the then stamp‐transferred each layer. By modularizing production assembly electrodes, laboratory‐scale achieves throughput 15 layers h −1 , maximum size 300×300 mm, tuning‐free compatibility with The batch‐spraying also provides unique capability to evaluate modify before they assembled into multilayer; method mechanically treating is employed increase breakdown strength Elastosil P7670 devices from 15.7 33.5 V µm . conductive up strain more than 200% add negligible stiffness multilayer structure. capabilities this produce useful demonstrated large‐area loudspeaker actuator 60 active layers.