Fabrication and applications of stimuli‐responsive micro/nanopillar arrays

Heterogeneous Silicone Nanorods with Region-Specific Functionality

Region-selective chemical modification of nano- and microstructures can unlock a world of novel functional surfaces. However, this small scale makes region selectivity challenging, especially on homogeneous and chemically inert synthetic structures. Here, we report the one-step in situ dynamic synthesis of heterogeneous multicomponent hybrid silicone nanorods (MCH-SNRs). These nanorods bear specific modifiable regions that can be assigned to different positions on-demand and selectively functionalized via a photoinitiated, radical-based thiol-ene click reaction. The distribution of different constituent components with desired properties hinges on the independent growth of the individual segment of the bamboo-shaped structure, which can be tailored by using different precursors under specific reaction conditions. Region selectivity of the functionalization is validated by exploiting wetting transitions along bamboo segments, visualized by confocal microscopy.

Realizing Square-Ordered Nanopillars with a 0.1-Tera-Density through a Superimposed Masking Strategy for Advanced Surface-Enhanced Raman Spectroscopy

Despite widespread interest in nanoscale pillar structures for various optical devices, including solar cells, photonic crystal lasers, and sensors, the critical challenges for mass production are the high equipment costs and limited scalability of traditional manufacturing methods. To overcome these hurdles, this study develops a simple and highly scalable etch-mask superposition technique based on thermally assisted nanotransfer printing (T-nTP) of Cr line patterns. The orthogonal superposition of linear Cr mask patterns creates double-height cross-point arrays that effectively and selectively protect the underlying SiO2 during subsequent reactive ion etching. This process generates highly uniform nanoscale pillar arrays with an extremely high density of 0.1 tera-pillars per square inch, eliminating the need for high-cost patterning platforms. As an exemplary application, we demonstrate the use of these perfectly ordered nanopillar arrays as high-performance surface-enhanced Raman scattering (SERS) sensors through the deposition of noble metal films on the nanopillar surface. These nanopillars enable exceptionally uniform SERS intensity with spot variations of less than 7% in methylene blue (MB) measurements. Additionally, they exhibit sensitive detections and accurate quantification for thiabendazole (TBZ) at concentrations as low as 10-8 M, along with multicycle reusability without noticeable degradation, owing to the outstanding robustness of the SiO2 nanopillars.

Superhydrophobic Magnetic-Driven Reactor for Microliter Droplet Reaction Interface Visualization

The development of an efficient, convenient, and cost-effective droplet-driven reactor to observe the reaction microphenomenon is crucial for investigating the chemical reaction and synthesis mechanisms. Herein, an efficient and economical strategy by combining micro-extrusion compression molding (μ-ECM) and surface modification was proposed to fabricate a superhydrophobic magnetic-driven reactor (SMDR) for microliter droplet reaction interface visualization. The wall-like array microstructures with favorable geometric uniformity and the nano-SiO2 coating with uniform dispersion endow the SMDR with robust superhydrophobicity, featuring a contact angle of 159.5 ± 1.0° and a rolling angle of 5.1 ± 0.5°. Due to the uniform dispersion of Fe3O4 in thermoplastic elastomer (TPE), the SMDR possesses sensitive magnetic responsiveness, which can drive droplets to move rapidly, continuously, and losslessly on horizontal and inclined planes, even on a plane with an inclination angle of up to 15°. Interestingly, the SMDR was successfully used to visualize the interface formation and evolution of three simple mixing/reaction processes, which provides a convenient, efficient, and low-cost method for the study of the droplet mixing reaction process and interface visualization.

Mesoscale polymer arrays: high aspect ratio surface structures and their digital reconstruction

Inspired by adhesive bio-filamentous structure, such as bacterial pili, this work details the methods used to fabricate and characterize a surface-anchored array of thin, flexible and shape-responsive mesoscale polymer ribbons with a length-to-thickness aspect ratio of up to 100 000. The resulting structures exhibit geometrically complex and dynamic morphologies consistent with elastocapillary bending that experience an increase in curvature over hours of aging due to creep. We develop a computational image analysis framework to generate 3D reconstructions of these densely crowded geometries and extract quantitative descriptors to demonstrate morphological changes due to aging. We demonstrate the robustness of this quantitative method by characterizing the creep-induced change in an aging ribbon array's shape and develop a scaling relationship to describe the importance of ribbon thickness for shape and dynamical observations. These methods demonstrate an essential baseline to probe morphology-property relationships of mesoscale polymer ribbon arrays fabricated from a variety of materials in numerous environments. Through the introduction of perfluorodecalin droplets, we illustrate the potential of these ribbon arrays towards applications in adhesive, microrobotic, and biomedical devices.

Stimuli-Mediated Macrophage Switching, Unraveling the Dynamics at the Nanoplatforms-Macrophage Interface

Macrophages play an essential role in immunotherapy and tissue regeneration owing to their remarkable plasticity and diverse functions. Recent bioengineering developments have focused on using external physical stimuli such as electric and magnetic fields, temperature, and compressive stress, among others, on micro/nanostructures to induce macrophage polarization, thereby increasing their therapeutic potential. However, it is difficult to find a concise review of the interaction between physical stimuli, advanced micro/nanostructures, and macrophage polarization. This review examines the present research on physical stimuli-induced macrophage polarization on micro/nanoplatforms, emphasizing the synergistic role of fabricated structure and stimulation for advanced immunotherapy and tissue regeneration. A concise overview of the research advancements investigating the impact of physical stimuli, including electric fields, magnetic fields, compressive forces, fluid shear stress, photothermal stimuli, and multiple stimulations on the polarization of macrophages within complex engineered structures, is provided. The prospective implications of these strategies in regenerative medicine and immunotherapeutic approaches are highlighted. This review will aid in creating stimuli-responsive platforms for immunomodulation and tissue regeneration.

Synergistic Inclusion Effects of Hard Magnetic Nanorods on the Magnetomechanical Actuation of Soft Magnetic Microsphere-Based Polymer Composites

The magnetomechanical actuation of micropillars is developed for the contactless manipulation of miniaturized actuators and microtextured surfaces. Anisotropic geometry of micropillars can significantly enhance the magnetic actuation compared with their isotropic counterparts by directional stress distributions. However, this strategy is not viable for triangular micropillars owing to insufficient anisotropy. In this study, a significant improvement in the magnetic actuation of triangular micropillars using composite magnetic particles is reported. A minute and optimal amount of hard magnetic gamma-ferrite nanorods are hybridized with soft magnetic iron microspheres to generate synergistic effects of magnetic coupling and percolation phenomenon on the magnetic actuation of polymer composites. The addition of 1 wt% face-centered cubic-phased gamma-ferrite nanorods suppresses the magnetic coupling interference of body-centered cubic-phased iron microspheres. Furthermore, the nanorods reduce the percolation threshold by participating in the percolation of the microspheres. A systematic compositional study on the magnetization and magnetorheological properties reveals that the coupling effect dominates the percolation effect at a low magnetic field, whereas the percolation effect governs the magnetic actuation at a high magnetic field. This hybrid approach can help in designing material constituents for effective magnetic actuators and robotic systems that can sensitively respond to an external magnetic field.

Programming Anisotropic Functionality of 3D Microdenticles by Staggered-Overlapped and Multilayered Microarchitectures

Natural sharkskin features staggered-overlapped and multilayered architectures of riblet-textured anisotropic microdenticles, exhibiting drag reduction and providing a flexible yet strong armor. However, the artificial fabrication of three-dimensional (3D) sharkskin with these unique functionalities and mechanical integrity is a challenge using conventional techniques. In this study, it is reported on the facile microfabrication of multilayered 3D sharkskin through the magnetic actuation of polymeric composites and subsequent chemical shape fixation by casting thin polymeric films. The fabricated hydrophobic sharkskin, with geometric symmetry breaking, achieves anisotropic drag reduction in frontal and backward flow directions against the riblet-textured microdenticles. For mechanical integrity, hard-on-soft multilayered mechanical properties are realized by coating the polymeric sharkskin with thin layers of zinc oxide and platinum, which have higher hardness and recovery behaviors than the polymer. This multilayered hard-on-soft sharkskin exhibits friction anisotropy, mechanical robustness, and structural recovery. Furthermore, coating the MXene nanosheets provides the fabricated sharkskin with a low electrical resistance of ≈5.3 Ω, which leads to high Joule heating (≈229.9 °C at 2.75 V). The proposed magnetomechanical actuation-assisted microfabrication strategy is expected to facilitate the development of devices requiring multifunctional microtextures.

Directional Rebound of Microdroplets on a Magneto-Responsive Micropillar Array Surface

The manipulation of droplet movement behavior is of scientific importance and has practical applications in many fields, such as biological analysis, water collection, oil-water separation, deicing, antifrosting, and so on. Using the magneto-responsive surface to dynamically change the surface morphology is an effective method to realize droplet manipulation. A replica molding technique was used to fabricate the surface with the magneto-responsive micropillar array, and the direction of the micropillar array could be changed dynamically with the magnetic induction intensity. The mechanism of the droplet directional rebound on the magneto-responsive surface and the implementation of the controllability of droplet movement were investigated. On the magneto-responsive surface, it was achievable to realize the directional rebound of droplets on the micrometer scale. The critical condition for the droplet directional rebound was identified. The force and energy of the droplet during the spreading and retraction stages were analyzed, which lay a theoretical foundation for the precise control of droplet directional rebound.

Self-Assembled Microactuators Using Chiral Liquid Crystal Elastomers

Materials that undergo reversible changes in form typically require top-down processing to program the microstructure of the material. As a result, it is difficult to program microscale, 3D shape-morphing materials that undergo non-uniaxial deformations. Here, a simple bottom-up fabrication approach to prepare bending microactuators is described. Spontaneous self-assembly of liquid crystal (LC) monomers with controlled chirality within 3D micromold results in a change in molecular orientation across thickness of the microstructure. As a result, heating induces bending in these microactuators. The concentration of chiral dopant is varied to adjust the chirality of the monomer mixture. Liquid crystal elastomer (LCE) microactuators doped with 0.05 wt% of chiral dopant produce needle-shaped actuators that bend from flat to an angle of 27.2 ± 11.3° at 180 °C. Higher concentrations of chiral dopant lead to actuators with reduced bending, and lower concentrations of chiral dopant lead to actuators with poorly controlled bending. Asymmetric molecular alignment inside 3D structure is confirmed by sectioning actuators. Arrays of microactuators that all bend in the same direction can be fabricated if symmetry of geometry of the microstructure is broken. It is envisioned that the new platform to synthesize microstructures can further be applied in soft robotics and biomedical devices.

Very High-Aspect-Ratio Polymeric Micropillars Made by Two-Photon Polymerization

Polymeric micropillars with a high-aspect-ratio (HAR) are of interest for a wide range of applications, including drug delivery and the micro-electro-mechanical field. While molding is the most common method for fabricating HAR microstructures, it is affected by challenges related to demolding the final structure. In this study, we present very HAR micropillars using two-photon polymerization (TPP), an established technique for creating complex 3D microstructures. Polymeric micropillars with HARs fabricated by TPP often shrink and collapse during the development process. This is due to the lack of mechanical stability of micropillars against capillary forces primarily acting during the fabrication process when the solvent evaporates. Here, we report different parameters that have been optimized to overcome the capillary force. These include surface modification of the substrate, fabrication parameters such as laser power, exposure time, the pitch distance between the pillars, and the length of the pillars. On account of adopting these techniques, we were able to fabricate micropillars with a very HAR up to 80.

Optimal Stopping Rules for Preventing Overloading of Multicomponent Systems

When random-strength components work as an interconnected parallel system, then its carrying capacity is random as well. In a case where such a multicomponent system is a subject of the stepwise-growing workload, some of its components fail and their loads are taken over by the ones that are intact. When the loading process is continued, the additional loads trigger consecutive failures that degrade the system, eventually leading to a complete failure. If the goal of the system is to carry as much load as possible, then the loading process should be continued, but no longer than until the loading capacity of the whole system is reached. On the other hand, with every additional load step, a failure of the system becomes more probable, as the carrying capacity is random and known solely through its probability distribution. In such cases, the decision on when to cease the loading process is not obvious. We introduce and analyse a minimal model of failure spreading in an array of progressively loaded pillars controlled by a decision-maker who stops the process when a required load is attained. We show how to construct an optimal stopping rule. Under some additional assumptions regarding the adopted loss function, it is argued that the optimal stopping rule is of the threshold type and it significantly depends on the shape of the load-step probability distribution.

Multi-Modal Locomotion of Caenorhabditis elegans by Magnetic Reconfiguration of 3D Microtopography

Miniaturized untethered soft robots are recently exploited to imitate multi-modal curvilinear locomotion of living creatures that perceive change of surrounding environments. Herein, the use of Caenorhabditis elegans (C. elegans) is proposed as a microscale model capable of curvilinear locomotion with mechanosensing, controlled by magnetically reconfigured 3D microtopography. Static entropic microbarriers prevent C. elegans from randomly swimming with the omega turns and provide linear translational locomotion with velocity of ≈0.14 BL s-1 . This velocity varies from ≈0.09 (for circumventing movement) to ≈0.46 (for climbing) BL s-1 , depending on magnetic bending and twisting actuation coupled with assembly of microbarriers. Furthermore, different types of neuronal mutants prevent C. elegans from implementing certain locomotion modes, indicating the potential for investigating the correlation between neurons and mechanosensing functions. This strategy promotes a platform for the contactless manipulation of miniaturized biobots and initiates interdisciplinary research for investigating sensory neurons and human diseases.

On-Demand Dynamic Chirality Selection in Flower Corolla-like Micropillar Arrays

Chiral morphology has been intensively studied in various fields including biology, organic chemistry, pharmaceuticals, and optics. On-demand and dynamic chiral inversion not only cannot be realized in most intrinsically chiral materials but also has mostly been limited to chemical or light-induced methods. Herein, we report reversible real-time magneto-mechanical chiral inversion of a three-dimensional (3D) micropillar array between achiral, clockwise, and counterclockwise chiral arrangements. Inspired by the flower corolla, achiral arrays of five and six radially arranged semicylindrical micropillars were employed as model systems to investigate the dynamic symmetry properties of arrays consisting of odd and even numbers of micropillars, respectively. Each micropillar underwent twisting actuation with a different twisting angle depending on the angle with the magnetic field direction and magnetic flux density, thereby collectively changing the chirality from the achiral to chiral state. Importantly, the morphological handedness of the micropillars was inverted within a few seconds by manipulating the direction of the magnetic field. A chiral morphology consisting of magnetically twisted micropillars was shape-fixed by the introduction of a polymeric binder. This binder could be simply washed off to return the shape-fixed twisted micropillars to their initial straight state. Magnetically programmable and reproducible 3D flower corolla-like micropillar arrays are expected to expand the potential of shape-reconfigurable devices that require real-time chiral manipulation in ambient environments.

Well-defined nanostructuring with designable anodic aluminum oxide template

Well-defined nanostructuring over size, shape, spatial configuration, and multi-combination is a feasible concept to reach unique properties of nanostructure arrays, while satisfying such broad and stringent requirements with conventional techniques is challenging. Here, we report designable anodic aluminium oxide templates to address this challenge by achieving well-defined pore features within templates in terms of in-plane and out-of-plane shape, size, spatial configuration, and pore combination. The structural designability of template pores arises from designing of unequal aluminium anodization rates at different anodization voltages, and further relies on a systematic blueprint guiding pore diversification. Starting from the designable templates, we realize a series of nanostructures that inherit equal structural controllability relative to their template counterparts. Proof-of-concept applications based on such nanostructures demonstrate boosted performance. In light of the broad selectivity and high controllability, designable templates will provide a useful platform for well-defined nanostructuring.

Well-defined nanostructuring is a feasible concept to achieve nanostructured arrays with unique properties. Here the authors report fabrication of designable anodic aluminum oxide templates with controllable in-plane and out-of-plane shapes, sizes, spatial configurations, and pore combinations.

Survivability of Suddenly Loaded Arrays of Micropillars

When a multicomponent system is suddenly loaded, its capability of bearing the load depends not only on the strength of components but also on how a load released by a failed component is distributed among the remaining intact ones. Specifically, we consider an array of pillars which are located on a flat substrate and subjected to an impulsive and compressive load. Immediately after the loading, the pillars whose strengths are below the load magnitude crash. Then, loads released by these crashed pillars are transferred to and assimilated by the intact ones according to a load-sharing rule which reflects the mechanical properties of the pillars and the substrate. A sequence of bursts involving crashes and load transfers either destroys all the pillars or drives the array to a stable configuration when a smaller number of pillars sustain the applied load. By employing a fibre bundle model framework, we numerically study how the array integrity depends on sudden loading amplitudes, randomly distributed pillar strength thresholds and varying ranges of load transfer. Based on the simulation, we estimate the survivability of arrays of pillars defined as the probability of sustaining the applied load despite numerous damaged pillars. It is found that the resulting survival functions are accurately fitted by the family of complementary cumulative skew-normal distributions.