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TWiki > RisePrivate Web>PrivateRiSE > ArtificialMuscles>FabricationTutorial (17 Nov 2010, SanjayDastoor)
These instructions are specific to acrylic actuator manufacturing, using VHB 4910 from 3M.

  1. Stretch films on stretching frame
    1. Usually stretch to 400% by 400% (aka, stretch 1mm x 1mm square to 4mm x 4mm), unless special reasons otherwise
    2. Add sharpie dots at border to aid in even stretching
    3. Do not stretch until ready to make actuators, to reduce likelihood of dust sticking to film
  2. Cut latex masks
    1. Should be a negative of the electrode mask, but may require small "sprues" to keep the mask a single sheet
    2. Take care to avoid touching the shiny side of the mask, to avoid transferring finger oils to the acrylic
    3. Clean shiny side with isopropyl or hexanes to remove residue from laser cutting
  3. Cut electrode masks
    1. Make sure terminal tabs are not overlapping (front vs back)
    2. Pay attention to symmetry of front vs back patterns (either make them square and symmetric, or keep track of which are front and which are back). Also, use mirror function in corel draw
  4. Cut actuator frames
    1. May want to sand or file edges to avoid sharp points coming into contact with the film
  5. Cut mounting frame
    1. Make sure the mounting attachment points line up with where the actuator frames will attach
    2. Best way to attach? Screws?
  6. Apply latex masks
    1. Make sure front and back masks line up with each other
  7. Apply latex and cure
    1. First dip brush into water to slightly wet. Should not be soaking or dripping wet.
    2. Dip brush into latex, making sure to remove excess using edge of can.
    3. Make even brush strokes and try to maintain consistent direction
  8. Apply electrode masks
  9. Mix electrode
    1. Electrode should start with x grams of carbon black and enough hexanes to submerge the carbon. Sonicate (in MERL Wet Shop) for 90 minutes
    2. In second container, dilute silicone oil in hexanes (25% silicone oil, 75% hexanes, or 1:3) and put on roller. Roll until mixture is even.
    3. In first container, add 4x grams of silicone oils. If using diluted mixture, add 16x grams of total mixture.
    4. Sonicate again for 90 minutes
  10. Spray electrode
    1. Connect compressed air line to sprayer (should be pressurized to 30-40 psi).
    2. Spray with even strokes, as far away from film as possible. Avoid wet spots.
    3. Spray until no light is visible through the film (only works for spraying the first side)
    4. Once done, spray out excess electrode mixture and then spray out hexanes to clean sprayer nozzle
  11. Apply grease
    1. Using q-tip. Don't apply too much
  12. Attach terminals
    1. 3cm piece of copper tape for each terminal. Make sure you get the kind that has conductive adhesive. Also try to prevent sharp corners from poking down into the film.
  13. Attach actuator frames
    1. Use superglue for acrylic and wood.
  14. Mount to mounting frames
  15. Cut/remove films from stretching frame
    1. Fresh x-acto blade makes sure the cut is clean and no sawing is necessary

 
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