This paper summarizes techniques for modeling geometric properties of THUNDER actuators which arise in the fabrication process. These actuators are high performance composites comprised of layers of piezoceramics in combination with aluminum, stainless steel, brass or titanium bonded with hot- melt adhesive. During the construction process, the assembly is heated under pressure to high temperatures, cooled and repoled to restore the actuator capabilities. This process provides the actuators with the robustness necessary to withstand the high voltages required for large displacement and force outputs. The process also provides the actuators with their characteristic curved shape. In this paper, relations between the thermal and electrostatic properties of the material and the final geometric configuration are quantified. This provides an initial model that can be employed in control applications which employ THUNDER actuators.
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