Electrochemical factors controlling the patterning of metals on SAM-coated substrates.

Alkanethiol self-assembled monolayers (SAMs) have been used in electrochemical microfabrication processes. The reductive desorption potential of alkanethiol SAMs, Edes, can be comparable to, greater than, or less than the metal reduction potential during electrodeposition, Emet. As a result, the SAM layer can passivate the surface or desorb simultaneously with metal deposition. We show that these electrochemical traits can be combined with a rastering microjet electrode to pattern SAMs directly and create patterned metal films without lithography steps. For the case of copper deposition on 1-octanethiol (OT)- and 1-dodecanethiol (DT)-coated substrates, Edes is significantly negative of Emet, resulting in high-resolution metal patterns with poor nucleation and poor adhesion to the substrate. However, nickel patterns deposited on 1-butanethiol (BT), OT, and DT have traits similar to bare gold (excellent nucleation and adhesion) because Edes is positive of Emet. Substrates with SAMs also suppress adventitious chemistries that occur distant from the rastering microjet electrode, such as oxygen reduction, making samples more corrosion resistant and improving the overall patterning process that we call electrochemical printing.

Investigation of heterogeneous electrochemical processes using multi-stream laminar flow in a microchannel.

A multi-component microfluidic electrochemical cell is shown to be a useful analytical tool for probing complex coupled processes in electrolytic systems. We recently reported an enzymatic signal amplification phenomenon that may provide increased sensitivity when detecting bio-analytes (M. S. Hasenbank, E. Fu and P. Yager, Langmuir, 2006, 22, 7451-7453), but to fully harness this method requires an improved understanding of the underlying electrochemical and chemical processes. We use spatial control of electrolyte streams on patterned conductive substrates in a microfluidic platform to elucidate the coupling of homogeneous chemical steps to heterogeneous electrochemical charge transfer processes. Because the gold surface was observable using SPR imaging, electrochemical phenomena could be monitored optically in real time. Based on these and additional results, we propose a mechanism for the novel amplification phenomenon that involves direct electron transfer between surface-immobilized enzyme molecules and the gold surface. This improved understanding of the underlying mechanism should enable the future implementation of this phenomenon in signal amplification schemes for highly sensitive lab-on-a-chip biosensors.