Additive manufacture of ionic polymer–metal composite actuators using digital light processing techniques

Abstract

Purpose The purpose of this study is to develop a additive manufacturing (AM) process for the fabrication of ionic polymer–metal composite (IPMC) devices with complex designs that would be time-consuming to replicate using conventional manual methods. These IPMC devices have considerable potential in electroactive polymers (EAPs) and soft actuators. Design/methodology/approach This paper presents a novel three–dimensional (3D) AM technique to develop IPMCs. Digital light processing (DLP) fabrication of soft EAPs was undertaken using a vat-based AM method, followed by deposition of cost-effective outer silver electrodes. Findings DLP-fabricated devices were compared to conventional Nafion™-117 devices. DLP layer-by-layer fabrication of these devices allowed for good resolution for a range of printed objects. Electrical actuation of the DLP-produced IPMCs showed tip displacements of up to 3 mm, and greater actuation was seen in the presence of lithium rather than magnesium cations. The IMPCs showed good ion exchange capacities, while electrochemical analysis showed the reversible formation and removal of AgCl layers in addition to ion movement. Practical implications The AM of these devices allows for rapid prototyping as well as potential use in the development of multiple degrees of freedom actuators and devices. Originality/value An original resin formulation was developed for DLP 3D printing. This formula is chemically distinct from the conventional Nafion™-117 membranes that can be purchased. Additionally, this method allows for the manufacture of complex objects that would be difficult to machine by hand. These findings are of value to both the fields of polymer chemistry and AM.