Forming electrical networks in three dimensions by self-assembly

Self-assembly of millimeter-scale polyhedra, with surfaces patterned with solder dots, wires, and light-emitting diodes, generated electrically functional, three-dimensional networks. The patterns of dots and wires controlled the structure of the networks formed; both parallel and serial connections were generated.

Prototyping of masks, masters, and stamps/molds for soft lithography using an office printer and photographic reduction

This paper describes a practical method for the fabrication of photomasks, masters, and stamps/molds used in soft lithography that minimizes the need for specialized equipment. In this method, CAD files are first printed onto paper using an office printer with resolution of 600 dots/in. Photographic reduction of these printed patterns transfers the images onto 35-mm film or microfiche. These photographic films can be used, after development, as photomasks in 1:1 contact photolithography. With the resulting photoresist masters, it is straightforward to fabricate poly(dimethylsiloxane) (PDMS) stamps/molds for soft lithography. This process can generate microstructures as small as 15 microm; the overall time to go from CAD file to PDMS stamp is 4-24 h. Although access to equipment-spin coater and ultraviolet exposure tool-normally found in the clean room is still required, the cost of the photomask itself is small, and the time required to go from concept to device is short. A comparison between this method and all other methods that generate film-type photomasks has been performed using test patterns of lines, squares, and circles. Three microstructures have also been fabricated to demonstrate the utility of this method in practical applications.

Dynamic self-assembly of magnetized, millimetre-sized objects rotating at a liquid-air interface

Spontaneous pattern formation by self-assembly is of long-standing and continuing interest not only for its aesthetic appeal, but also for its fundamental and technological relevance. So far, the study of self-organization processes has mainly focused on static structures, but dynamic systems--those that develop order only when dissipating energy--are of particular interest for studying complex behaviour. Here we describe the formation of dynamic patterns of millimetre-sized magnetic disks at a liquid-air interface, subject to a magnetic field produced by a rotating permanent magnet. The disks spin around their axes with angular frequency equal to that of the magnet, and are attracted towards its axis of rotation while repelling each other. This repulsive hydrodynamic interaction is due to fluid motion associated with spinning; the interplay between attractive and repulsive interactions leads to the formation of patterns exhibiting various types of ordering, some of which are entirely new. This versatile system should lead to a better understanding of dynamic self-assembly, while providing a test-bed for stability theories of interacting point vortices and vortex patches.

Self-Assembly of Hexagonal Rod Arrays Based on Capillary Forces.

A series of well-ordered, extended mesostructures has been generated from hexagonal polyurethane rods (15x3.2 mm) by self-assembly using capillary forces. The surface of one or more sides of the rods was rendered hydrophilic by exposure to an oxygen plasma. This modification determined the pattern of hydrophobic and hydrophilic faces; the hydrophobic sides were coated with a thin film of a hydrophobic lubricant. Agitation of the rods in an approximately isodense aqueous environment resulted in their self-assembly, in a process reflecting the action of capillary forces, into an array whose structure depends on the pattern of hydrophobic sides; capillarity also aligned the ends of the rods. We also carried out experiments in reaction chambers that restricted the motion of the rods; this restriction served to increase the size and regularity of the assemblies. Copyright 2000 Academic Press.

Fabrication of metallic microstructures using exposed, developed silver halide-based photographic film

This paper demonstrates that the pattern of silver particles embedded in the gelatin matrix of exposed and developed silver halide-based photographic film can serve as a template in a broadly applicable method for the microfabrication of metallic microstructures. In this method, a CAD file is reproduced in the photographic film by exposure and developing. The resulting pattern of discontinuous silver grains is augmented and made electrically continuous by electroless deposition of silver, and the electrically continuous structure is then used as the cathode for electrochemical deposition of an additional layer of the same or different metal. The overall process can be completed within 2 h, starting from a CAD file, and can generate electrically continuous structures with the smallest dimension in the plane of the film of approximately 30 microns. Structures with aspect ratio of up to 5 can also be obtained by using the metallic structures as photomasks in photolithography using SU-8 photoresist on the top of the electroplated pattern and exposed from the bottom, followed by development and electroplating through the patterned photoresist. This method of fabrication uses readily available equipment and makes it possible to develop prototypes of a wide variety of metallic structures and devices. The resulting structures--either supported on the film backing or freed from it--are appropriate for use as passive, structural materials such as wire frames or meshes and can also be used in microfluidic, microanalytical, and microelectromechanical systems.

Mirrorless lasing from mesostructured waveguides patterned by soft lithography

Mesostructured silica waveguide arrays were fabricated with a combination of acidic sol-gel block copolymer templating chemistry and soft lithography. Waveguiding was enabled by the use of a low-refractive index (1.15) mesoporous silica thin film support. When the mesostructure was doped with the laser dye rhodamine 6G, amplified spontaneous emission was observed with a low pumping threshold of 10 kilowatts per square centimeter, attributed to the mesostructure's ability to prevent aggregation of the dye molecules even at relatively high loadings within the organized high-surface area mesochannels of the waveguides. These highly processible, self-assembling mesostructured host media and claddings may have potential for the fabrication of integrated optical circuits.

Macroscopic, Hierarchical, Two-Dimensional Self-Assembly.

By tailoring capillary interactions at a fluid-fluid interface, a hierarchical two-dimensional self-assembly of hexagonal millimeter-sized poly(dimethylsiloxane) plates has been demonstrated (see picture). The strength and direction of capillary forces between plates was controlled by patterning of the surfaces of the plates to be hydophobic or hydrophilic. The thick lines indicate hydrophobic faces whose mutual attraction forms the basis of capillarity.

Microfabrication inside capillaries using multiphase laminar flow patterning

The reaction of species in solutions flowing laminarly (without turbulent mixing) inside capillaries was used as the basis for a broadly applicable method of microfabrication. In this method, patterning occurs as a result of transport of reactive species to interfaces within the capillary by laminar flow. A wide range of chemistries can be used to generate structures with feature sizes of less than 5 micrometers and with spatial localization to within 5 micrometers. The method is applicable to the patterning of metals, organic polymers, inorganic crystals, and ceramics on the inner walls of preformed capillaries, using both additive and subtractive processes.

Design and self-assembly of open, regular, 3D mesostructures

Self-assembly provides the basis for a procedure used to organize millimeter-scale objects into regular, three-dimensional arrays ("crystals") with open structures. The individual components are designed and fabricated of polyurethane by molding; selected faces are coated with a thin film of liquid, metallic alloy. Under mild agitation in warm, aqueous potassium bromide solution, capillary forces between the films of alloy cause self-assembly. The structures of the resulting, self-assembled arrays are determined by structural features of the component parts: the three-dimensional shape of the components, the pattern of alloy on their surfaces, and the shape of the alloy-coated surfaces. Self-assembly of appropriately designed chiral pieces generates helices.

Hierarchically ordered oxides

Porous silica, niobia, and titania with three-dimensional structures patterned over multiple length scales were prepared by combining micromolding, polystyrene sphere templating, and cooperative assembly of inorganic sol-gel species with amphiphilic triblock copolymers. The resulting materials show hierarchical ordering over several discrete and tunable length scales ranging from 10 nanometers to several micrometers. The respective ordered structures can be independently modified by choosing different mold patterns, latex spheres, and block copolymers. The examples presented demonstrate the compositional and structural diversities that are possible with this simple approach.

Design and fabrication of topologically complex, three-dimensional microstructures

Two concepts for use in the fabrication of three-dimensional (3D) microstructures with complex topologies are described. Both routes begin with a two-dimensional (2D) pattern and transform it into a 3D microstructure. The concepts are illustrated by use of soft lithographic techniques to transfer 2D patterns to cylindrical (pseudo-3D) substrates. Subsequent steps-application of uniaxial strain, connection of patterns on intersecting surfaces-transform these patterns into free-standing, 3D, noncylindrically symmetrical microstructures. Microelectrodeposition provides an additive method that strengthens thin metal designs produced by patterning, welds nonconnected structures, and enables the high-strain deformations required in one method to be carried out successfully.

Self-Assembly of Mesoscale Objects into Ordered Two-Dimensional Arrays

Regular arrays of topologically complex, millimeter-scale objects were prepared by self-assembly, with the shapes of the assembling objects and the wettability of their surfaces determining the structure of the arrays. The system was composed of solid objects floating at the interface between perfluorodecalin and water and interacting by lateral capillary forces; patterning of the wettability of the surfaces of the objects directs these forces. Self-assembly results from minimization of the interfacial free energy of the liquid-liquid interface. Calculations suggest that this strategy for self-assembly can be applied to objects on a micrometer scale.

Complex Optical Surfaces Formed by Replica Molding Against Elastomeric Masters

Complex, optically functional surfaces in organic polymers can be fabricated by replicating relief structures present on the surface of an elastomeric master with an ultraviolet or thermally curable organic polymer, while the master is deformed by compression, bending, or stretching. The versatility of this procedure for fabricating surfaces with complex, micrometer- and submicrometer-scale patterns was demonstrated by the production of (i) diffraction gratings with periods smaller than the original grating; (ii) chirped, blazed diffraction gratings (where the period of a chirped grating changes continuously with position) on planar and curved surfaces; (iii) patterned microfeatures on the surfaces of approximately hemispherical objects (for example, an optical surface similar to a fly's eye); and (iv) arrays of rhombic microlenses. These topologically complex, micropatterned surfaces are difficult to fabricate with other techniques.