Progress in research and development in the field of electro-active polymers has enabled prototype fabrication, which demonstrates the future potential and versatility offered by this technology. These prototypes can be qualified as laboratory demonstrators. A new design of dielectric elastomer linear actuators is presented here. These actuators have the unique properties of being self-supporting and core-free. They are capable of large push forces and are fabricated based on large-scale industrial manufacturing processes. Actuators can be easily scaled to fit specific application needs. Actuator design and construction principles, as well as modelling are presented and discussed for push InLastor  actuators. The actuators exhibit modest strokes and high actuation forces. Current design considerations indicate that the achievable force output is reduced by about 40% due to the passive ends of the actuator. Dielectric electro-active polymer DEAP film manufacturing challenges contribute to reducing the achievable breakdown strength to 35 V µm −1 and limit the strain to modest figures. It is shown that push InLastor actuators can be operated at field strength levels above 45 V µm −1 , and exhibit larger strokes and forces in good agreement with the model. At these elevated electric field levels, risks of catastrophic breakdown increase, resulting in reduced actuator lifetime. A major milestone in the manufacturing of actuators based on the DEAP technology has been achieved by Danfoss PolyPower. Large-scale manufacturing of robust and reliable push tubular actuators is possible. Roll-to-roll manufacturing processes make it possible to manufacture these powerful actuators, based on PolyPower compliant electrode design.

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DEAP Actuator structures are being developed and optimized with focus on high volume automated manufacturing techniques and processes. New core-free and self-supporting structures are capable of providing PUSH forces without external mechanical tension mechanisms or film pre-strain. Fundamental actuator design and construction principles are presented. A simple quasi-static model governing behaviour is presented and actual results from this new class of push actuator devices are compared to modelled behaviour. These actuators have the capability of modest stroke and high actuation forces. Actuators can be easily scaled to fit the application based upon physical size and force-stroke relationship.

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