Piezoelectric ceramics enable fast, precise, and powerful actuation with integrated sensing in insect-scale robots. However, they are brittle, failing at low strains limiting its applications involving high impacts, unexpected loading, or soft robotics. To address this limitation, we investigate polyvinylidene fluoride (PVDF) as a compliant alternative: it tolerates substantially larger strains, but its low piezoelectric coefficient limits the output of conventional single-layer actuators. We demonstrate a novel manufacturing process for multilayer PVDF actuators that utilizes off the shelf materials and provides parallel bussing of signal voltage to reduce integration complexity. Using first principles models validated with experiments, we show a tradeoff between force (linear or superlinear increase with layer count) and displacement (cubic decrease with layer count) for the actuator geometry chosen. Our work positions PVDF actuation an optimization problem for future robotic applications with clear design knobs available to meet performance demands. Further, we show that using thinner PVDF layers within a stack increases the specific power density of the actuators making them ideal for size, weight, and power (SWAP) limitations in small scale robotics. Among the actuators fabricated, >9 mm of free deflection, >20 mN of blocked force, and >500 Hz bandwidth were achieved. To illustrate their potential in future robust robotic platforms, we integrate our actuators into a low-profile insect-scale robot that leverages resonance to achieve planar locomotion while being robust to large external impacts.

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