Search Results (60)

Copper (Cu) thin films and meshes on polyethylene terephthalate (PET) substrates are promising flexible transparent conductive electrodes (TCEs), yet their practical use is limited by insufficient interfacial adhesion and poor oxidative stability on inert polymer substrates. This work addresses these issues via a synergistic strategy of interfacial layer engineering and maskless laser lithography-based aperiodic mesh patterning, systematically comparing ceramic (Al₂O₃) and metallic (NiCr) interfacial layers for PET-supported Cu films and fabricating Linear/Sinusoidal aperiodic Cu meshes with tailored performance. Magnetron sputtering shows that Ar plasma-activated NiCr interfacial layers form a gradient-alloyed interface with Cu via interdiffusion, achieving 5B-level adhesion, mitigating bending-induced stress concentration, and enhancing damp-heat resistance (85 °C/85% RH) by suppressing oxidation—outperforming brittle Al₂O₃ layers. Patterning the optimized Cu/NiCr/PET structure into micrometer-scale meshes yields a Linear design with superior optoelectronic performance (~10.8 Ω/sq sheet resistance, >87% transmittance at 550 nm) and a Sinusoidal design with enhanced bending robustness via stress delocalization. Microstructural and elemental analyses clarify the NiCr layer’s interfacial toughening and anti-oxidation mechanisms. Practical validation in flexible transparent heaters demonstrates rapid thermal response and >20 h continuous operational stability. This study provides a scalable design strategy for high-performance PET-supported Cu meshes, offering insights for interface and structural optimization of flexible metallic TCEs for next-generation optoelectronics. Full article

Superhydrophobic surfaces have gained considerable attention due to their ability to repel water and reduce surface adhesion, and they are now widely applied for self-cleaning, anti-fouling, anti-icing, and corrosion resistance purposes. In this study, either a computer numerical control (CNC) machine or photolithographic techniques were employed to fabricate molds with microwells, followed by soft lithography to obtain a polydimethylsiloxane (PDMS) micropillar array. An etching process was then carried out. It was found that, as etching time increased, the diameters of micropillars decreased, leading to a decrease in the solid fraction of the composite surface and increases in contact angles. When the ratios of spacing to diameter (W/D) and of height to diameter (H/D) both exceeded 1.5, the contact angle was found to exceed 150° and the original PDMS micropillar surface with a contact angle of around 135° became superhydrophobic. A drastic decrease in sliding angle was also observed at this threshold. Changes in contact angles with different W/D values were in good agreement with values calculated using the Cassie–Baxter equation, and the droplet state was verified by a pressure balance model. Meanwhile, the PDMS etching rate when using acetone as the solvent was approximately 6–8 times faster than that when using 1-Methyl-2-pyrrolidone (NMP), a result which is comparable to data in the literature. Full article

Conformal electronics are distinguished by their unique characteristics, such as the integration of structure and function and their conformability with complex geometries. These features unlock a broad spectrum of applications, including structural health monitoring and the creation of metasurfaces. However, the current landscape of large-scale curved electronic fabrication is characterized by a significant gap in specialized equipment and standardized strategies. In this context, we introduce a pioneering strategy that leverages robotized electrohydrodynamic (EHD) printing for the conformal fabrication of large-scale curved electronics on 3D surfaces. This comprehensive multi-robot EHD conformal printing strategy integrates several critical components, including plasma surface treatment, EHD conformal printing, and near-infrared (NIR) sintering processes. These are supported by enabling technologies such as 3D surface reconstruction and precise hybrid positioning. Notably, our strategy achieves 5 µm printing resolution via EHD lithography and 35 µm repeatable positioning accuracy. After plasma treatment, conductive patterns on FR4 substrates reach 5B-level adhesion strength. NIR sintering enables high-efficiency sintering within only 125 s. Seamless integration of these processes into multi-robot collaborative equipment enables the fabrication of large-area conformal electronics, such as 400 mm × 1000 mm unmanned aerial vehicle wings and 650 mm × 350 mm satellite shells, and supports multi-layer systems including wires, LED arrays, antennas, and sensors. This strategy possesses substantial potential to transcend the limitations inherent in traditional fabrication methods, paving the way for new frontiers in conformal electronics across a variety of applications, including smart wings and satellite surfaces. Full article

This publication presents an improved manufacturing method for tetrahedral metal effect pigment particles that demonstrates reduced flowlines in injection-molded polymer components compared with conventional platelet-shaped pigment particles. The previously published cold forming process for tetrahedral particles, made entirely from aluminum, faced manufacturing challenges, resulting in a high reject rate due to particle adhesion to the micro-structured mold roller. In contrast, this study introduces a new manufacturing method for tetrahedral particles, now consisting of metallized UV-cured thermoset polymer. These particles, dispersed in amorphous matrix thermoplastics, have shown to maintain their shape during the injection molding process. The manufacturing technique for these novel particles is based on UV imprint lithography, omitting the reject rates compared with the previously presented cold rolling process of tetrahedral full aluminum particles. Thus, the novel manufacturing technique for tetrahedral pigment particles shows increased potential for automation through roll-to-roll manufacturing in the future. Full article

Adhesion of different microorganisms to the surface of dental materials has generated significant interest since one of the most important requirements of biomaterials to be considered successful is their ability to withstand the damage caused by microorganisms that may lead to failure and the onset of different pathologies, such as caries. In vitro testing has demonstrated that surface modification is an alternative approach to reduce the adhesion of microorganisms to surfaces. The objective of this work was to assess the adhesion of Streptococcus mitis, Streptococcus mutans, and Candida albicans to a dental composite surface modified following a biomimetic approach and coated with salivary proteins. Soft lithography was used to copy the topography from the Crocosmia aurea leaf and then transfer it to the surface of dental composite discs that were coated with saliva proteins. Surfaces were characterized by contact angle and atomic force microscopy. S. mitis, S. mutans, and C. albicans were used to assess bacterial and fungal adhesion in monoculture and co-culture. The topographic modification of the surface of a dental composite reduced the adhesion of assessed microorganisms and the adhesion of these species in monoculture and co-culture on saliva-coated surfaces was higher than on topographically modified surfaces. Full article

Directed cell migration is crucial for numerous biological processes, including tissue regeneration and cancer metastasis. However, conventional symmetrical micropatterns typically result in bidirectional cell migration guidance instead of unidirectional guidance. In this study, polydimethylsiloxane (PDMS)-based platforms with asymmetrical arrowhead micropatterns, nanopillars, and selective fibronectin coating were developed to enhance unidirectional cell migration. The platforms were fabricated using nanoimprint lithography and PDMS replication techniques, allowing for precise control over surface topography and biochemical modification. The MC3T3 osteoblastic cells cultured on these platforms demonstrated significantly enhanced directional migration, characterized by increased displacement, and directional alignment with micropattern orientation compared to symmetrical patterns. Quantitative analyses revealed that asymmetrical arrowheads combined with nanopillars induced more focal adhesions and F-actin polarization at cell front regions, supporting the observed unidirectional cell migration enhancement. These results confirm that integrating micropattern asymmetry, nanoscale features, and biochemical functionalization synergistically promotes unidirectional cell migration. The developed platforms offer valuable insights and practical strategies for designing advanced biomaterials capable of precise spatial cell guidance that can be applied to the designs of organ-on-a-chip systems. Full article

Direct-writing submicron copper circuits on glass with laser precision—without lithography, vacuum deposition, or etching—represents a transformative step in next-generation microfabrication. We present a high-resolution, maskless method for metallizing glass using ultrashort pulse Bessel beam laser processing, followed by silver ion activation and electroless copper plating. The laser-modified glass surface hosts nanoscale chemical defects that promote the in situ reduction of Ag⁺ to metallic Ag⁰ upon exposure to AgNO₃ solution. These silver seeds act as robust catalytic and adhesion sites for subsequent copper growth. Using this approach, we demonstrate circuit traces as narrow as 0.7 µm, featuring excellent uniformity and adhesion. Compared to conventional redistribution-layer (RDL) and under-bump-metallization (UBM) techniques, this process eliminates multiple lithographic and vacuum-based steps, significantly reducing process complexity and production time. The method is scalable and adaptable for applications in transparent electronics, fan-out packaging, and high-density interconnects. Full article

Nowadays, the Internet of Things (IOT), electronics, and neural interfaces are becoming an integral part of our life. These technologies place unprecedentedly high demands on materials in terms of their mechanical and electrical properties. There are several strategies for forming conductive layers in such composites, e.g., volume blending to achieve a percolation threshold, inkjet printing, lithography, and laser processing. The latter is a low-cost, environmentally friendly, scalable way to produce composites. In our work, we synthesized AgNW and characterized them using Ultraviolet-visible spectroscopy (UV-vis), Transmission electron microscopy (TEM), and Selective area electron diffraction (SAED). We found that our AgNW absorbed in the UV-vis range of 345 to 410 nm. This is due to the plasmon resonance phenomenon of AgNW. Then, we applied the dispersion of AgNW on the surface of the polymer substrate, dried them and we got the films of AgNW.. We irradiated these films with a 432 nm laser. As a result of the treatment, we observed two processes. The first one was the sintering and partial melting of nanowires under the influence of laser radiation, as a consequence of which, the sheet resistance dropped more than twice. The second was the melting of the polymer at the interface and the subsequent integration of AgNW into the substrate. This allowed us to improve the adhesion from 0–1 B to 5 B, and to obtain a composite capable of bending, with radius of 0.5 mm. We also evaluated the shielding efficiency of the obtained composites. The shielding efficiency for 500–600 nm thick porous film samples were 40 dB, and for 3.1–4.1 µm porous films the shielding efficiency was about 85–90 dB in a frequency range of 0.01–40 GHz. The data obtained by us are the basis for producing flexible electronic components based on AgNW/PET composite for various applications using laser processing methods. Full article

This review focuses on the innovative use of laser techniques in developing and functionalizing biomimetic surfaces, emphasizing their potential applications in the medical and biological fields. Drawing inspiration from the remarkable properties of various natural systems, such as the water-repellent lotus leaf, the adhesive gecko foot, the strong yet lightweight spider silk, and the unique optical structures of insect wings, we explore the potential for replicating these features through advanced laser surface modifications. Depending on the nature and architecture of the surface, particular techniques have been designed and developed. We present an in-depth analysis of various methodologies, including laser ablation/evaporation techniques, such as Pulsed Laser Deposition and Matrix-Assisted Pulsed Laser Evaporation, and approaches for laser surface structuring, including two-photon lithography, direct laser interference patterning, laser-induced periodic surface structures, direct laser writing, laser-induced forward transfer, and femtosecond laser ablation of metals in organic solvents. Additionally, specific applications are highlighted with the aim of synthesizing this knowledge and outlining future directions for research that further explore the intersection of laser techniques and biomimetic surfaces, paving the way for advancements in biomedical applications. Full article

This study aimed to assess the suitability of printed zirconia (ZrO₂) for adhesive cementation compared to milled ZrO₂. Surface conditioning protocols and disinfection effects on bond strength were also investigated. ZrO₂ discs (n = 14/group) underwent either alumina (Al₂O₃) airborne particle abrasion (APA; 50 µm, 0.10 MPa) or tribochemical silicatisation (TSC; 110 µm Al₂O₃, 0.28 MPa and 110 µm silica-modified Al₂O₃, 0.28 MPa), followed by disinfection (1 min immersion in 70% isopropanol, 15 s water spray, 10 s drying with oil-free air) for half of the discs. A resin cement containing 10-methacryloyloxydecyl dihydrogen phosphate (10-MDP) was used for bonding (for TSC specimens after application of a primer containing silane and 10-MDP). Tensile bond strength was measured after storage for 24 h at 100% relative humidity or after 30 days in water, including 7500 thermocycles. Surface conditioning significantly affected bond strength, with higher values for TSC specimens. Ageing and the interaction of conditioning, disinfection and ageing also impacted bond strength. Disinfection combined with APA mitigated ageing-related bond strength decrease but exacerbated it for TSC specimens. Despite these effects, high bond strengths were maintained even after disinfection and ageing. Adhesive cementation of printed ZrO₂ restorations exhibited comparable bond strengths to milled ZrO₂, highlighting its feasibility in clinical applications. Full article

Soft lithography has long remained the state of the art to generate the necessary micropatterning for molded microfluidic (MF) chips. Previous attempts to use printed circuit boards (PCBs) as a cheap and accessible alternative to expensive lithographed molds for the production of PDMS MF chip prototypes have shown their limitations. A more in-depth exploration of using PCBs as a mold substrate and a novel methodology of using flexible PCBs to produce highly accurate MF chips is reported here for the first time. Cross sections highlight the improved accuracy of this method, and peel testing is performed to demonstrate suitable adhesion between the glass substrate and PDMS cast. Positive cell growth viability showcases this novel method as a high-accuracy, high-accessibility, low-cost prototyping method for microfluidic chips while still maintaining all favorable properties provided by the PDMS material. Full article

The thickness of the coating on the surface of a workpiece is an important factor in determining the quality of spraying. However, it is challenging to estimate the distribution of film thickness accurately before the actual spraying process. This lack of estimation hinders the optimization of spraying process parameters and trajectory. To overcome this, a numerical simulation of surface spray coating thickness was conducted to provide guidance for the actual coating process. The research consists of three main parts. Firstly, the spray trajectory of the spray gun is determined using the proposed Stereo Lithography (STL) model slicing algorithm. Secondly, a two-phase flow spray model and collision adhesion model are established to construct the spray film model. The surface mesh is determined, and the spraying process parameters are set. Finally, numerical simulation is conducted to analyze the dynamic spraying trajectory and the distribution of coating thickness. The results show that the coating thickness distribution on an arc surface is thicker in the middle and thinner on the edges. The distribution is symmetric with respect to both the transverse and longitudinal directions of the arc surface. The coating thickness distribution at both ends is not as uniform as in the middle section. The concave part of the free surface has the largest coating thickness, while the coating thickness distribution on the convex part is not as uniform as on the relatively flat part. This method of simulating the coating thickness distribution on complex surfaces provides a solid foundation for further optimization of spraying process parameters and trajectory, ultimately improving the qualification rate of workpiece spraying processing. Full article

This paper presents a novel microfluidic dielectrophoresis (DEP) system to focus and separate cells of similar size based on their structural differences, which is more challenging than separation by size. Because, in this case, the DEP force is only proportional to the polarizabilities of cells, we used live and dead yeast cells as bio-particles to investigate the chip efficiency. Our designed chip consists of three sections. First, we focused on cells at the center of the microchannel by employing a negative DEP phenomenon. After that, cells were separated due to the different deflection from high-electric-field areas. Finally, a novel outlet design was utilized to facilitate separation by increasing the gap between the two groups of cells. The proposed sheath-free design has one inlet for target cell injection requiring only one pump to control the flow rate, which reduces costs and complexity. Successful discrimination of the particles was achieved by using DEP force as a label-free and highly efficient technique. As an accessible and cost-effective method, soft lithography with a 3D-printed resin mold was used to fabricate the microfluidic parts. The microchannel was made of polydimethylsiloxane (PDMS) material that is biocompatible. The electrodes were made of gold due to its biocompatibility and non-oxidation, and a titanium layer was sputtered as the buffer layer for the adhesion of the sputtered gold layer to the glass. A standard microfabrication process was employed to create the electrode pattern. O₂ plasma treatment yielded leakage-free bonding between the patterned glass and PDMS structure containing the microfluidic channel. The maximum voltage applied to the electrodes (26 V) was lower than the threshold value for cell electroporation. The simulations and experimental results both confirm the effectiveness of the proposed microfluidic chip. Full article

Bacterial adhesion to the surface of materials is the first step in biofilm formation, which will lead to conditions that may compromise the health status of patients. Recently, polydopamine (PDA) has been proposed as an antibacterial material. Therefore, the objective of the current work was to assess and compare the adhesion of Streptococcus mutans to the surface of poly(methyl methacrylate) (PMMA) discs that were modified using PDA following a biomimetic approach versus smooth PDA-coated PMMA surfaces. In addition, an assessment of the growth inhibition by PDA was performed. PMMA discs were manufactured and polished; soft lithography, using the topography from the Crocosmia aurea leaf, was used to modify their surface. PDA was used to smooth-coat PMMA discs by dip-coating. The growth inhibition was measured using an inhibition halo. The surfaces were characterized by means of atomic force microscopy (AFM), the contact angle (CA), and Fourier-transform infrared spectroscopy (FTIR). Polydopamine exhibited a significant antibacterial effect when used directly on the S. mutans planktonic cells, but such an effect was not as strong when modifying the PMMA surfaces. These results open the possibility of using polydopamine to reduce the adhesion and growth of S. mutans, which might have important consequences in the dental field. Full article

Micro- and nanopatterns perform unique functions and have attracted attention in various industrial fields, such as electronic devices, microfluidics, biotechnology, optics, sensors, and smart and anti-adhesion surfaces. To put fine-patterned products to practical use, low-cost patterning technology is necessary. Nanoimprint lithography (NIL) is a promising technique for high-throughput nanopattern fabrication. In particular, thermal nanoimprint lithography (T-NIL) has the advantage of employing flexible materials and eliminating chemicals and solvents. Moreover, T-NIL is particularly suitable for compostable and recyclable materials, especially when applying biobased materials for use in optics and electronics. These attributes make T-NIL an eco-friendly process. However, the processing time of normal T-NIL is longer than that of ultraviolet (UV) NIL using a UV-curable resin because the T-NIL process requires heating and cooling time. Therefore, many studies focus on improving the throughput of T-NIL. Specifically, a T-NIL process based on a roll-to-roll web system shows promise for next-generation nanopatterning techniques because it enables large-area applications with the capability to process webs several meters in width. In this review, the T-NIL process, roll mold fabrication techniques, and various materials are introduced. Moreover, metal pattern transfer techniques using a combination of nanotransfer printing, T-NIL, and a reverse offset are introduced. Full article