Efficient and flexible fabrication is critical to facilitate experimental research of dielectric elastomer actuators (DEAs). As a rapid prototyping technique, additive manufacturing enables autonomous fabrication of DEAs with controlled geometry and distributed actuation. Contact dispensing is currently the most utilized additive manufacturing method for fully printed DEAs due to its capability to utilize a wide range of materials. However, modest contact dispensing printers produce DEAs with reliable actuation by fabricating thicker dielectric layers. There is an evident need for other approaches to increase actuation performance and lower the driving voltage. While utilization of particulate dielectric composites is a known technique to increase DEA performance, it is not widely applied for 3D printed DEAs. Adverse effects of 3D printed dielectric particulate composites, such as stiffening and material flow interruption, can be diminished with lower operational strains and thicker layers, respectively. Additionally, composite DEAs with improved performance often possess lower driving voltage due to lower breakdown strength. In this study, various dielectric composites properties, such as compressive Young’s modulus, permittivity, and breakdown strength, were examined to evaluate the electromechanical performance of unimorph DEAs through the figures of merit (FOMs). Breakdown strength of both blade-casted films and 3D printed actuators were compared. Particle distribution was monitored using a scanning electron microscope. Unimorph DEAs with plain silicone and dielectric composites were fabricated using HYREL 30M printer. Printed actuators showed improved electromechanical performance and lowered the driving voltage.
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