Novel Silicone Rubber–Based Multi-Dimensional Filler Composite Electrode Materials for the Dielectric Elastomer Actuation Technology of Micro-Crawling Robots

Aiming to develop high-performance flexible electrode materials for dielectric elastomer actuation systems applied to micro-crawling robots, this study proposes multi-dimensional filler composite electrode materials with a methyl vinyl silicone rubber matrix. Three types of conductive fillers—namely, zero-dimensional super-conductive carbon black, one-dimensional single-walled carbon nanotubes, and two-dimensional flaky micron-sized silver powder—were employed to construct a hierarchical multi-dimensional conductive network within the silicone rubber matrix via a three-stage fabrication strategy. The electrical conductivity and conductive stability of the as-prepared composite electrode materials were systematically investigated, where the intrinsic mechanisms and evolutionary laws of material electrical performance variations were analyzed. Furthermore, the effects of fillers with different dimensional morphologies on the comprehensive properties of the composites at each fabrication stage were explored, and the optimal filler dosage for each component was determined. Microstructural observations of the staged conductive network formation further verified the rationality of the stage-based functional design model. The optimized composite electrode delivers an initial electrical conductivity of 1.5 × 104 S/m, with only a 14.9% conductivity attenuation under 50% tensile strain, demonstrating excellent electromechanical stability. Moreover, a prototype micro-crawling robot was fabricated using the optimized composite electrode, achieving a maximum linear crawling speed of 8 mm/s. These experimental results validate the feasibility and superiority of the proposed multi-dimensional filler composite strategy. This work provides a novel technical approach for the design and development of high-performance flexible electrode materials for flexible electronic and micro-robotic actuation applications.