Hybrid Fabrication of Prestrain-Locked Acrylic Dielectric Elastomer Thin Films and Multilayer Stacks

Dielectric elastomers based on commercial acrylic dielectric elastomers (VHB adhesive films) are widely investigated for soft actuators due to their large electrically driven actuation strain and high work density. However, the VHB films require prestretching to overcome electromechanical instability, which adds fabrication complexity. In addition, their high viscoelasticity leads to a low response speed. Interpenetrated polymer networks (IPNs) are developed to lock the prestrain in VHB films, resulting in free-standing films that are capable of large-strain actuation. In this work, a prestrain-locked high-performance dielectric elastomer thin film (VHB-IPN-P) by introducing 1,6-hexanediol diacrylate to create an IPN in the VHB network and a plasticizer to enhance the actuation speed is reported. VHB-IPN-P based actuators exhibit stable actuation at 60% strain up to 10 Hz and reach a peak energy density of 102 J kg⁻¹ . In addition, a hybrid process is also developed for the fabrication of multilayer stacks of VHB-IPN-P with strong inter-layer bonding and structural integrity. Four-layer stacks fabricated preserve the strain and energy density of single-layer VHB-IPN-P films but with linearly scaled force and work output.