Recent experiments and simulations have demonstrated the feasibility of active boundary layer control in turbulent flows. Reduction of skin friction drag requires the development of sensors, actuators and control algorithms to favorably modify the boundary layer close to the wall. In this work, the actuator side of the problem is addressed, with the goal of developing a realistic actuation technology for boundary layer control experiments, and eventually, for use in real boundary layer control applications. Design issues in flow control applications are discussed. A process for fabricating arrays of zero mass flux vortex generators is described. Finally, the mechanical and fluid dynamic characteristics of the actuators are presented.