Search Results (238)

Metasurfaces, planar structures made on a subwavelength scale, enable state-of-the-art manipulation of light and have become a promising solution for compact optical devices. However, fabrication of these nanoscale structures relies on demanding processes, limiting their integration into diverse structures, including three-dimensional ones. In this study, we develop a manufacturing and transfer technique that renders the manipulation and deposition of metasurfaces achievable with high freedom by embedding the nanostructure into a flexible polymer matrix. A metasurface consisting of a TiO₂ nanoparticle array fabricated by nanoimprint lithography was encapsulated within a poly(methyl methacrylate) (PMMA) layer through spin-coating. The layer containing the metasurface was then detached from the original SiO₂ substrate using wet-etching, becoming a free-standing soft sheet carrying nanostructures that can be transferred onto various surfaces. After the transfer, the layer thickness was further tuned through reactive ion etching to modulate the optical response. Incident-angle-resolved transmittance exhibited no significant change in optical bands before and after transfer, confirming that the nanostructure, as well as the photonic band, was well preserved. Thickness reduction of the PMMA cladding induced a clear optical resonance shift, demonstrating controllability of the optical response. This approach provides a versatile route for the installation of metasurfaces and expands the design possibilities for nanophotonic devices. Full article

Resin 3D-printed molds are being increasingly favored for PDMS microfluidics across many disciplines. However, resin diversity, as well as secret manufacturer formulations, leads to a lack of standardization when using 3D printing for microscale applications. The impact of physical resin properties, both in its monomeric concoction and polymerized lattices at 100 µm or lower scales, needs quantification. We tested the performance of locally available resin formulations, isolating the impact of resin pigments and how it impacted the resin’s properties and performance. Lower resin viscosity improved feature fidelity (edge filleting < 25 µm) and improved resolution limit for recessed features, while cured polymer mechanical strength impacted the limit for positive mold features. We combined our findings to fabricate quality negative and positive mold structures in the mold and determined the best protocols associated with limitations during the fabrication of such structures. The methodologies in this study are expected to be widely applicable across various resin types and simplify the adoption of 3D printing protocols for specific feature fabrication in microscale molds for PDMS devices. Full article

Paper-based microfluidic devices (μPADs) have attracted significant attention for point-of-care testing (POCT), environmental monitoring, and food safety due to their low cost, ease of use, and minimal instrument dependence. However, fabricating high-resolution and reproducible microchannels on paper remains challenging. Conventional methods such as wax printing, photolithography, and inkjet printing are limited by resolution or equipment cost. Here, we present a low-cost, high-resolution fabrication method for μPADs, termed wax soft lithography, which combines wax printing with soft lithography. Through this method, microchannels with a minimum width of 234 ± 62 μm were consistently produced, and complex patterns were successfully fabricated, demonstrating high precision and reproducibility. As a proof-of-concept demonstration of device functionality, the fabricated μPADs were used to detect glucose in spiked urine samples, showing a concentration-dependent colorimetric response. This method provides an effective route for rapid production of high-resolution μPADs in resource-limited settings. With further validation before practical applications, this method shows promise for future development in POCT. Full article

Microfluidics provides precise control of microscale fluid transport and has become central to biomedical, pharmaceutical, and industrial technologies. However, conventional fabrication methods such as photolithography and soft lithography require cleanroom facilities, use costly materials, and offer limited capability for constructing complex or multi-material architectures. This review highlights emerging manufacturing strategies, focusing on polymer-based micro-milling as an accessible and cost-effective alternative for microfluidic device production. Advances in micro-milling now enable the fabrication of microchannels and functional features with improved dimensional accuracy and surface quality, while additive manufacturing offers complementary rapid prototyping and design flexibility. Micro-milling is particularly promising for rapid prototyping of polymeric biosensor chips designed for point-of-care diagnostics. The technique supports diverse materials and eliminates reliance on cleanroom processing. Critical parameters, including tool geometry, spindle speed, and feeding rate, strongly influence fidelity and surface roughness, which directly affect biosensor sensitivity. Despite its advantages, challenges such as tool wear, burr formation, and limits on minimum feature size continue to hinder reproducibility. Recent progress in toolpath optimization, hybrid additive–subtractive methods, and real-time process monitoring shows the potential to overcome these barriers. Overall, micro-milling offers a scalable and economical route for fabricating accessible microfluidic and biosensing platforms, with future work needed to standardize processes and improve integration with surface functionalization methods. Full article

Microcontact stamping is a promising microfabrication technique for producing functional patterned thin films on flexible substrates; however, systematic optimization of its process parameters for thermochromic applications remains limited. In this study, we present a comprehensive parametric optimization of the microcontact stamping process to fabricate thermochromic pigment-coated thin films with rapid and reversible color responses. The effects of liquid resin type, SU-8 mold thickness, polydimethylsiloxane (PDMS) mixing ratio, and pattern size on pattern fidelity and thermochromic performance were systematically investigated. The optimal conditions were identified as a UV-curable resin, a 600 µm-thick SU-8 mold, a PDMS base-to-curing-agent ratio of 5:1, and a pattern size of 125 × 125 µm². Under these conditions, the stamped thermochromic films exhibited uniform micro-patterns, rapid response and recovery behavior, and stable reversible color changes over 20 consecutive thermal cycles. This work provides practical guidelines for parameter-controlled microcontact stamping of functional thin films and demonstrates its potential for scalable fabrication of thermochromic micro-patterns. The proposed approach is expected to contribute to the development of flexible and wearable electronic devices, smart displays, and thermally responsive sensing platforms. Full article

Microbial biofilms pose significant health risks by causing infections associated with prosthetic and indwelling medical devices. Factors such as the high tolerance levels of biofilm microorganisms to antibiotics and the inability of antimicrobial agents to penetrate the biofilm matrix render antibiotic-based treatment methods ineffective against biofilm-related infections. Surfaces patterned with nanoscale topographical features have shown promising results in controlling the attachment of microorganisms. Therefore, nanopatterning of surfaces provides an excellent alternative to the existing antibiotic-based therapies. There are many techniques, such as photolithography and soft lithography, for patterning polymer or metal surfaces. However, depending on the cost, toxicity, feature size, and material compatibility, these methods have limitations. Although hydrogels have garnered special interest as biomaterials due to their biocompatibility and resemblance to the natural biological environment, hydrogels with surface nanopatterns have not been widely investigated as anti-biofouling materials. The applicability of hydrogels in biomedical applications and the importance of inhibiting microbial biofilms underscore the need for further research into the manufacturing of nanoengineered hydrogels with diverse topographical features. In this review, we discuss how nanostructured hydrogels inhibit biofilm formation. Further, we discuss nanopatterning methods, their limitations, advantages, and disadvantages. This article also highlights the current state of research on nanostructured hydrogels and associated challenges. 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

Surface functionalisation of polymers is essential for enhancing properties such as wettability and mechanical resistance. This study presents a scalable, coating-free approach to fabricate hydrophobic and superhydrophobic Polydimethylsiloxane (PDMS) surfaces. Aluminium (AA2024) moulds were microstructured using a TruMicro femtosecond laser system to generate grid patterns with controlled hatch distances and depths, as well as laser-induced periodic surface structures (LIPSSs). These features were accurately replicated onto PDMS, as confirmed by scanning electron miscoscopy (SEM) and profilometry. Contact angle measurements showed a marked increase in hydrophobicity, reaching superhydrophobicity for optimised parameters, with surface stability maintained over four months without degradation. Full article

The integration of artificial intelligence (AI) and micro/nanorobotics is fundamentally reshaping biosensing by enabling autonomous, adaptive, and high-resolution biological analysis. These miniaturized robotic systems fabricated using advanced techniques such as photolithography, soft lithography, nanoimprinting, 3D printing, and self-assembly can navigate complex biological environments to perform targeted sensing, diagnostics, and therapeutic delivery. AI-driven algorithms, mainly those in machine learning (ML) and deep learning (DL), act as the brains of the operation, allowing for sophisticated modeling, genuine real-time control, and complex signal interpretation. This review focuses recent advances in the design, fabrication, and functional integration of AI-enabled micro/nanorobots for biomedical sensing. Applications that demonstrate their potential range from quick point-of-care diagnostics and in vivo biosensing to next-generation organ-on-chip systems and truly personalized medicine. We also discuss key challenges in scalability, energy autonomy, data standardization, and closed-loop control. Collectively, these advancements are paving the way for intelligent, responsive, and clinically transformative biosensing systems. Full article

Strain-promoted azide–alkyne cycloaddition (SPAAC) is widely used in solution-phase bioconjugation. However, its application in surface chemistry remains limited because substrate-independent azide films that remain stable upon reaction with bulky strained alkynes have not yet been developed. In this study, we address this challenge using a melanin-inspired coating based on tyrosine–azide derivatives with different linkers. In particular, we investigated how differences in linker length and hydrophilicity affect the hydrophobic interactions within the film network and, ultimately, determine film stability. Specifically, Tyr-3-N₃, a tyrosine–azide derivative having an azide group tethered to tyrosine through a short three-carbon alkyl linker, was identified as optimal, forming azide-presenting films via tyrosinase-mediated oxidation and retaining integrity during SPAAC with external dibenzocyclooctyne (DBCO) ligands. The optimized poly(Tyr-3-N₃) coatings enabled efficient methoxypolyethylene glycol (mPEG) immobilization, thereby exhibiting excellent antifouling performance against protein adsorption, and further supported spatially controlled protein patterning through soft lithography techniques such as micromolding in capillaries (MIMIC) and microcontact printing (µCP). The approach was broadly applicable with a range of inorganic and polymeric substrates, as well as living cell surfaces; even after encapsulation and SPAAC-based functionalization, the cells remained viable. Collectively, these findings establish a substrate-independent and biocompatible coating platform that preserves film stability through SPAAC functionalization, supporting applications in antifouling coatings, biosensing, and cell surface engineering. 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

In optical one-dimensional grating-on-layer planar structures, an optical resonance occurs when the incident light wave becomes phase-matched to a leaky waveguide mode excited in the layer underneath the grating by an appropriate tuning of the grating periodicity. Changing the refractive indices of the grating’s constituents, and/or thickness, changes the resonance frequency. In the case of a two-dimensional grating atop such a smooth layer, a similar and also cavity-mode resonance can occur. This idea has straightforward usage in diverse optical sensor applications. In this study, a novel guided-mode resonance sensor design for detecting glucose and hemoglobin in minute concentrations at a wide range of incidence angles is presented. In this design, materials of the grating, such as a polymer and cesium-lead halide with a perovskite crystal structure, are examined, which will allow flexible, low-cost fabrication by soft-lithography/imprint-lithography methods. The sensitivity, figure of merit, and quality factor are reported for one- and two-dimensional grating structures. The simulations performed are based on rigorous coupled-wave analysis. Optical resonance quality factor of ∼$5·{10}^5$ is achieved at oblique incidence for a structure comprising a one-dimensional grating etched in a poly-vinylidene chloride layer atop a silicon nitride waveguide layer on a substrate. Record values of the above-noted characteristics are achieved with a synergetic interplay of the materials, structural dimensions, incidence angle, polarization, and grating geometry. 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

We present a simple, rapid and low-cost multi-layer mold fabrication method for production of polydimethylsiloxane (PDMS) lab-on-chip (LOC) devices. The new approach offers resource-strained researchers access to microfluidic lab-on-chip fabrication for medical diagnostics, food security and environmental monitoring applications. In this work, photomasks were designed on PowerPoint (2021) and printed on Pelikan transparency sheets using a Canon PIXMA iX6840 Inkjet printer. The photomasks were then tested for ultraviolet (UV) transmission and compared to the masks produced for circuit board manufacture. Another low-cost approach for the alignment of multi-exposure masks was also developed and tested by producing three-layer photoresist pyramid-like structures on silicon (Si) wafer using the soft lithography process. Full article

Continuous monitoring of glucose (CGM) level is of utmost importance to diabetic patients, especially with no or minimal pain. Microneedle arrays with desired electrode patterns have been fabricated by soft lithographic molding, and the patterned electrodes were formed via shadow evaporation through a shadow mask that was made from a modified molding technique. With immobilization of glucose oxidase (GOx), the microneedle electrode arrays (MEAs) have been successfully employed for the in vitro CGM using impedance spectroscopy. The fabricated MEAs could monitor the varying glucose level continuously for up to ~10 days. Similar processes have been applied for the fabrication of stretchable MEAs, which can conform to complex curvilinear surfaces. The simple and low-cost fabrication of MEAs, either in flexible or stretchable forms, may find various applications in wearable health monitoring techniques. Full article