A Novel Computer-Controlled Maskless Fabrication Process for Pneumatic Soft Actuators

Template-based and additive manufacturing techniques have demonstrated some fabrication routes for creating pneumatic soft actuators. However, as the complexity and capability of the actuators continue to develop, the limitations of these approaches are becoming evident. These include difficulties for design variations, process speed and resolution, material compatibility and scalability, which hinder and restrict both the possible capabilities of the technology and its transition from research to industry. This body of work presents a computer-controlled, maskless manufacturing process with a different approach to allow for high-speed, low-cost and flexible creation of pneumatic soft actuation networks comprising multi-material construction. This was investigated through a bespoke fabrication platform that provides computer-controlled localised plasma treatment to selectively modify the chemical behaviour on the surface of silicone and polyethylene terephthalate (PET) bodies. The altered surface chemistry facilitated selective bond formation between the treated parts of the surface and, consequently, greater design variation and control over the pneumatic chambers that were formed. Selective treatment patterns allowed nonlinear pneumatic chamber designs to be created, and the strength of bonded silicone structures was shown to facilitate large deformations in the actuators. Furthermore, the different interactions between the plasma and silicone were leveraged to achieve feature sizes of