Fabrication

The Textile Silicone Hybrid Sensors are made of two conductive knit fabric electrode layers surrounding a dielectric layer of silicone elastomer. The sensor layers are constructed using a batch manufacturing process described in the subsequent pages. An automatic film applicator is used to create a thin layer of elastomer and a fabric sheet is bonded to the top surface. After curing, the unfinished sensor is flipped over and the process is repeated on the other side. This process is able to create sheets of sensor mats as large as the film applicator used. The mats can then be cut into arbitrary, customizable, individual sensors. This method of batch manufacturing creates sensors with nearly identical performance in a repeatable and controllable way that is scaleable for rapid, robust, and reliable production of large sensor sheets. 

Overview of Steps

	Using a film applicator cast a sheet of elastomer that will become the dielectric layer of the sensor.
	Pour and cast another layer onto the dielectric. This will act as an adhesive layer.
	Lay fabric electrode layer on top and roll to flatten the fabric. Cure this layer of the sensor.
	After curing peel the unfinished sensor off of the tray.
	Flip the unfinished sensor over to face the silicone side up. Secure with masking tape.
	Cast onto the second side of the silicone using another batch of elastomer.
	Place the second piece of fabric and cure completely.
	Peel the sensor from the tray.
	Sensor Mat is finished!