The thickness-dependent response of aerosol-jet-printed ultrathin high-aspect-ratio electrochemical microactuators

Trilayer electrochemical actuators comprising an electrolyte layer sandwiched between two electrode layers have been shown to exhibit large deformations at low actuation voltages. Here we report the aerosol-jet printing (AJP) of high-aspect-ratio bending-type trilayer electrochemical microactuators comprised of Nafion as the electrolyte and poly(3,4-ethylenedioxythiophene)polystyrene sulfonate (PEDOT:PSS) as the electrode. We investigated how the thicknesses of the electrolyte and electrode layers affect the DC response of these actuators by fabricating high-aspect-ratio trilayer cantilevers with varied layer thicknesses (0.36 μm to 1.9 μm-thick electrodes, and 3.5 μm to 12 μm-thick electrolyte layers). We found that the transported charge and angular deflection are proportional to the applied voltage at steady state, and the charge-to-voltage ratio scales with the PEDOT:PSS thickness. The deflection-to-voltage ratio is found to be strongly affected by the Nafion electrolyte thickness, showing a decreasing trend, but is less affected by the PEDOT:PSS thickness in the range of dimensions fabricated. The timescales for deflection are found to be generally longer than the timescales for charge transfer and no clear trend is observed with respect to layer thicknesses. This work establishes an experimental protocol in geometry optimisation of printed electrochemical microactuators, verifies the applicability of a theoretical model, and lays the groundwork for designing and optimising more sophisticated printed electrochemical microactuation systems.