This mixture was then poured into two separate casts: The cavity cast (above) and the cell cast (below), both which we printed on MakerBot Replicator 2s using these .stl files at this link.
When casting the base (top picture), it was necessary to place a piece of paper within the silicon. This was done to ensure the rigidness of the based upon actuation.
When we tried casting our first actuator, a lot of silicone leaked from the crack between the mold halves -- the website says nothing about this. After emptying it out to try again, we noticed that the silicone that was left near the edges cured in the meantime, preventing new leaks.
A video of the casting process:
After pouring the silicon, it must be left to cure. Although the material specifies 16 hours at room temperature, our application takes closer to 6.
After drying, the actuators were coerced out of their molds, glued together with additional silicon, and tested... and it worked!
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