Dielectric elastomer transducers (DETs) consist of thin elastomer films and compliant conductive electrodes on each side. Several DE-based systems, e.g., DE actuators, loudspeakers or sensors, have great potential in industrial applications. Different manufacturing processes for DE-based transducers have been realized so far. An alternative manufacturing process, based on sheet-to-sheet lamination of pre-fabricated elastomer films, appears promising for the manufacturing of large numbers of DETs, as, on the one hand, the commercially available elastomer films produced are characterized by homogeneous and reproducible properties and, on the other hand, the curing time during processing can be avoided. However, the handling of thin elastomer films and a controlled film transfer onto a surface is a challenge, as pre-stretch and wrinkles can easily occur. The presented sheet-to-sheet lamination mechanism facilitates controllable film handling well, whereby a high number of DE layers can be achieved. This paper focuses on the developed, automated film lamination of pre-cut film sheets and the electrode application via a jetting system, representing core components of the corresponding overall manufacturing process of DE laminates. The process realization on a laboratory scale is presented and manufactured DET specimens investigated for validation purposes.

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