Hierarchical structure formation and pattern replication induced by an electric field

Rapid In-Plane Pattern Growth for Large-Area Inverse Replication Through Electrohydrodynamic Instability of Polymer Films

Nanopatterning driven by electrohydrodynamic (EHD) instability can aid in the resolution of the drawbacks inherent in conventional imprinting or other molding methods. This is because EHD force negates the requirement of physical contact and is easily tuned. However, its potential has not examined owing to the limited size of the pattern replica (several to tens of micrometers). Thus, this study proposes a new route for large-area patterning through high-speed evolution of EHD-driven pattern growth along the in-plane axis. Through the acceleration of the in-plane growth, while selectively controlling a specific edge growth, the pattern replica area can be extended from the micro- to centimeter scale with high fidelity. Moreover, even in the case of nonuniform contact mode, the proposed rapid in-plane growth mode facilitates uniform large-scale replication, which is not possible in conventional imprinting or other molding methods.

Rapid Electrohydrodynamic-Driven Pattern Replication over a Large Area via Ultrahigh Voltage Pulses

Despite the prospects of electrohydrodynamic instability patterning (EHIP), poor process parameter controllability is a significant challenge in uniform large-scale nanopatterning. Herein, we introduce a EHIP process using an ultrahigh electric field (>108 V/m) to effectively accelerate the pattern growth evolution. Owing to the strong dependence on a temporal parameter (1/τm) of the field strength, our method not only reduces the completion time of pattern growth but also overcomes critical parametric restrictions on the pattern replication, thereby enhancing the replicated pattern quality in three dimensions. The pattern can be uniformly replicated over the entire film surface even without a perfectly uniform air gap, which has been severely difficult in the conventional method. To further demonstrate how straightforward yet versatile our approach is, we applied our EHIP approach to successfully replicate the densely packed nanostructures of cicada wings.

Micropatterned functional interfaces on elastic substrates fabricated by fixing out of plane deformations

We report on the preparation of micropatterned functional surfaces produced by inducing an out-of-plane deformation on elastic substrates and fixing these by creating a rigid oxidized top layer. Specifically, the elastic substrate used was Polydimethylsiloxane (PDMS) and the rigid layer on top was created by ozonation of this material. We evidenced that the surface pattern formed is directly dependent on the pressure applied, the mechanical properties of the elastic substrate and on the dimensions and shape of the mask employed to define the exposed and non-exposed areas. In addition to the pattern formed, another interesting aspect is related to the ozone diffusion within the material. Softer PDMS enables more efficient diffusion and produced a thicker oxidized layer in comparison to rigid PDMS. Finally, a simulation was carried out using the distribution of Von Misses stresses of a solid plate to understand the conditions in which the applied force resulted in the rupture of the rigid oxidized layer under a permanent deformation.

Pattern formation in thin polymeric films via electrohydrodynamic patterning

The free surface of a thin polymeric film is often unstable and deforms into various micro-/nano-patterns under an externally applied electric field. This paper reviews a recent patterning technique, electrohydrodynamic patterning (EHDP), a straightforward, cost-effective and contactless bottom-up method. The theoretical and numerical studies of EHDP are shown. How the characteristic wavelength and the characteristic time depend on both the external conditions (such as voltage, film thickness, template-substrate spacing) and the initial polymer properties (such as rheological property, electrical property and surface tension) is theoretically and experimentally discussed. Various possible strategies for fabricating high-aspect-ratio or hierarchical patterns are theoretically and experimentally reviewed. Aligning and ordering of the anisotropic polymers by EHDP is emphasized. A perspective, including novelty and limitations of the methods, particularly in comparison to some conventional patterning techniques, and a possible future direction of research, is presented.

Manipulation of a Nonconductive Droplet in an Aqueous Fluid with AC Electric Fields: Droplet Dewetting, Oscillation, and Detachment

Electrowetting (EW) is an effective method for droplet manipulation in microfluidics. In traditional EW, a conductive droplet is actuated, which spreads on a solid substrate. Recently, we considered an opposite phenomenon of droplet actuation in EW: inducing nonconductive droplet dewetting and detaching from the substrate. An oil/water system is used in which the oil droplet (nonconductive) is actuated on a flat substrate in surrounding water (conductive) by EW. In this work, alternating current (AC) electric fields are applied to EW, and the transient dynamics of droplet dewetting, oscillation, and detachment with the AC signals are investigated. The droplet is not in contact with electrodes, and it dances freely on the substrate. Experiments are performed in a wide range of voltages and AC frequencies. To demonstrate the droplet dynamics, we divide the full process of droplet manipulation into three distinguishable periods, that is, an initiating period, a steady oscillation period, and a detaching condition. Transient droplet dewetting is considered in the initiating period, and we obtain the distribution of the contact line friction factor. In steady oscillation, the oscillation resonance is verified from the oscillating amplitude of the contact line. Different periodical features are found for the droplet dancing at the resonance frequencies and departure from resonance. The droplet is detached at high voltages, and we provide a map for the detachable and nondetachable zones. The voltage is the dominant factor determining the droplet detachment; however, the AC frequency has notable influences on the critical voltage. The detachment is promoted when the AC frequency is within the region of the oscillation resonance (e.g., 20 < f < 75 Hz). In this region, the detaching process is not monotonic but instead, the droplet rebounds by several times before it is completely detached.

Programmed topographical features generated on command in confined electroactive films

This work describes a method to create dynamic pre-programmed surface textures by an alternating electric field on coatings that consist of a silicon oxide reinforced viscoelastic siloxane network. The finite element method is developed to predict the complex deformation figures and time-resolved experimental topographical surface analysis is used to confirm them.

Self-organization of random copolymers to nanopatterns by localized e-beam dosing

Strategic electron beam (e-beam) irradiation on the surface of an ultrathin (<100 nm) film of polystyrene-poly(methyl methacrylate) (PS-PMMA) random copolymer followed by solvent annealing stimulates a special variety of dewetting, leading to large-area hierarchical nanoscale patterns. For this purpose, initially, a negative (positive) tone of resist PS (PMMA) under weak e-beam exposure is exploited to produce an array of sites composed of cross-linked PS (chain-scissioned PMMA). Subsequently, annealing with the help of a developer solvent engenders dewetted patterns in the exposed zones where PMMA blocks are confined by the blocks of cross-linked PS. The e-beam dosage was systematically varied from 180μC cm^-2to 10 000μC cm^-2to explore the tone reversal behavior of PMMA on the dewetted patterns. Remarkably, at relatively higher e-beam dosing, both PMMA and PS blocks act as negative tones in the exposed zone. In contrast, the chain scission of PMMA in the periphery of the exposed regions due to scattered secondary electrons caused confined dewetting upon solvent annealing. Such occurrences eventually lead to pattern miniaturization an order of magnitude greater than with conventional thermal or solvent vapor annealed dewetting. Selective removal of PMMA blocks of RCP using a suitable solvent provided an additional 50% reduction in the size of the dewetted features.

Non-equilibrium thermal annealing of a polymer blend in bilayer settings for complex micro/nano-patterning

Micro phase separation in a thin film of a polymer blend leads to interesting patterns on different substrates. A plethora of studies in this field discussed the effect of the surface energy of the underlying tethered polymer brush or substrate on the final morphology of the polymer blend. The conventional process toward the final morphology is rather slow. Here, aiming fast lithography, we induce the kinetically driven morphological evolution by rapid thermal annealing (RTA) of the polymer blend of polystyrene (PS) and polymethylmethacrylate (PMMA) in bilayer settings at a very high temperature. The underlying film consists of untethered constituent homopolymers or their blend or random-co-polymer (RCP). Apart from the phase inversion of the blend on the PS homopolymer, a rich morphology of the blend on the RCP underlayer is uncovered with systematic investigation of the film using sequential washing with selective solvents. The dissolution characteristics and the thermal stability of the constituent polymers corroborated the observation. Based on the understanding of the morphological evolution, fabrication of a complex shaped micro/nano-pattern with multiple length scales is demonstrated using this blend/RCP system. This study shows a novel methodology for easy fabrication of hierarchical small length scale complex structures.

Parametric scheme for rapid nanopattern replication via electrohydrodynamic instability

Electrohydrodynamic (EHD) instability patterning exhibits substantial potential for application as a next-generation lithographic technique; nevertheless, its development continues to be hindered by the lack of process parameter controllability, especially when replicating sub-microscale pattern features. In this paper, a new parametric guide is introduced. It features an expanded range of valid parameters by increasing the pattern growth velocity, thereby facilitating reproducible EHD-driven patterning for perfect nanopattern replication. Compared with conventional EHD-driven patterning, the rapid patterning approach not only shortens the patterning time but also exhibits enhanced scalability for replicating small and geometrically diverse features. Numerical analyses and simulations are performed to elucidate the interplay between the pattern growth velocity, fidelity of the replicated features, and boundary between the domains of suitable and unsuitable parametric conditions in EHD-driven patterning. The developed rapid route facilitates nanopattern replication using EHD instability with a wide range of suitable parameters and further opens up many opportunities for device applications using tailor-made nanostructures in an effective and straightforward manner.

1/τ_m-dependent electrohydrodynamic replication of a hexagonally ordered hole array nanopattern by adjusting the filling ratio. As the 1/τ_m increases, the morphology evolves into the perfectly replicated hole features with increasing filling ratio.

Electric Field Enhances Shear Resistance of Polymer Melts via Orientational Polarization in Microstructures

In this paper, we studied the alteration of viscoelastic properties of a neat poly(methyl methacrylate) (PMMA), induced by an applied external electric field. The rheological properties of PMMA are measured using a rotational rheometer at elevated temperatures. The electric field effect on the shear resistance of the polymer was studied by examining rheological responses under difference experimental scenarios. We find that the external electric field can remarkably enhance shear resistance and prevent flow of PMMA melt, enabling it to behave more predictably at high temperatures. Dynamic rheological analysis illustrates that the external electric field speeds up the recovery of mechanical properties of the PMMA melt after large deformations, whereas the PMMA melt exhibits thixotropic behaviors. The recovery velocity is influenced by the strength of the electric field, specifically, and is found to be proportional to the electric field strength. Our experimental characterization may provide new evidence on the tuning mechanical properties of polymer melts via controlling segmental polarization.

Bistable colloidal orientation in polar liquid near a charged wall

We examine the translation and rotation of an uncharged spheroidal colloid in polar solvents (water) near a charged flat surface. We solve the nonlinear Poisson-Boltzmann equation outside of the colloid in two dimensions for all tilt angles θ with respect to the surface normal. The colloid's size is assumed to be comparable to the Debye's length and hence field gradients are essential. The Maxwell stress tensor, including the ideal gas pressure of ions, is integrated over the colloid's surface to give the total force and torque on the colloid. From the torque we calculate the effective angular potential U_eff(θ). The classical behavior where the colloid tends to align in the direction perpendicular to the surface (parallel to the field, θ=0) is retrieved at large colloid-surface distances or small surface potentials. We find a surprising transition whereby at small separations or large potentials the colloid aligns parallel to the surface (θ=90°). Moreover, this colloid orientation is amplified at a finite value of the aspect ratio. This transition may have important consequences to flow of colloidal suspensions or as a tool to switch layering of such suspensions near a surface.

Micro-to-nanometer patterning of solution-based materials for electronics and optoelectronics

Technologies for micro-to-nanometer patterns of solution-based materials (SBMs) contribute to a wide range of practical applications in the fields of electronics and optoelectronics. Here, state-of-the-art micro-to-nanometer scale patterning technologies of SBMs are disseminated. The utilisation of patterning for a wide-range of SBMs leads to a high level of control over conventional solution-based film fabrication processes that are not easily accessible for the control and fabrication of ordered micro-to-nanometer patterns. In this review, various patterning procedures of SBMs, including modified photolithography, direct-contact patterning, and inkjet printing, are briefly introduced with several strategies for reducing their pattern size to enhance the electronic and optoelectronic properties of SBMs explained. We then conclude with comments on future research directions in the field.

Electrodynamic-contact-line-lithography with nematic liquid crystals for template-less E-writing of mesopatterns on soft surfaces

We report the development of a single-step, template-less and fast pathway, namely, Electrodynamic-Contact-Line-Lithography (ECLL), to write micro to nanopatterns on the surface of a soft polymer film. As a model system, a layer of nematic liquid crystals (NLC), resting on a polymer thin film, was sandwiched between a pair of electrodes emulating the electrowetting on a dielectric (EWOD) setup. Upon the application of electric field, the Maxwell stresses thus generated at the NLC-polymer interface due to the high dielectric contrast stimulated an unprecedented fingering instability at the advancing NLC-polymer-air contact line. In the process, the advancing electrospreading front of NLC left the footprint of an array of micro to nanoscale wells on the polymer surface with a long-range ordering thus unveiling a pathway for maskless patterning of a soft elastic film. Unlike the conventional electric field induced lithography (EFL), the meso-scale morphology was found to follow the short wavelength-scales as the periodicity of the patterns (λ_c) varied linearly with the thickness of the film (h), (λ_c∝h). The high dielectric contrast at the NLC-polymer interface and the local fluctuation of the NLC directors ensured a time scale much faster than the same observed for the polymer-air systems.

Subnanometer imaging and controlled dynamical patterning of thermocapillary driven deformation of thin liquid films

Exploring and controlling the physical factors that determine the topography of thin liquid dielectric films are of interest in manifold fields of research in physics, applied mathematics, and engineering and have been a key aspect of many technological advancements. Visualization of thin liquid dielectric film topography and local thickness measurements are essential tools for characterizing and interpreting the underlying processes. However, achieving high sensitivity with respect to subnanometric changes in thickness via standard optical methods is challenging. We propose a combined imaging and optical patterning projection platform that is capable of optically inducing dynamical flows in thin liquid dielectric films and plasmonically resolving the resulting changes in topography and thickness. In particular, we employ the thermocapillary effect in fluids as a novel heat-based method to tune plasmonic resonances and visualize dynamical processes in thin liquid dielectric films. The presented results indicate that light-induced thermocapillary flows can form and translate droplets and create indentation patterns on demand in thin liquid dielectric films of subwavelength thickness and that plasmonic microscopy can image these fluid dynamical processes with a subnanometer sensitivity along the vertical direction.

Reversible morphological switching and deformation hysteresis in electric field mediated instability of thin elastic films

Reversible morphology switching in a soft elastic film sandwiched between two parallel electrodes when subject to an externally applied electric field is reported herein. In contrast to electric field mediated instability of a thin liquid film, where the instability patterns remain permanent, in the present case the patterns debond completely or partially when the electric field is switched off, depending on whether the gap spacing (dG) between the film and the top electrode is >100 nm or not. The onset of instability is marked with the appearance of isotropic columns when the applied field strength (U) exceeds a critical value (Uc). The subsequent increase in U leads to the gradual transition of the instability patterns from pillars to bi-continuous labyrinths to an array of holes. Complete conformal contact is established between the film and the top electrode at U = UF. When U is reduced, the morphology changes in a reverse sequence. There is a significant level of hysteresis between the bonding and debonding stages, including persistence of the features at much lower voltages due to pinning of the patterns to the top electrode. Complete detachment occurs at a lower voltage UD when dG > 100 nm. The holes fluctuate before complete contact between the film and the top electrode due to competition between the destabilizing electric field and restoring forces due to stretching of the crosslinked polymer matrix.

Growth of Polystyrene Pillars in Electric Field

Surface patterning on polymer films, which is a self-assembly process under the action of external and/or internal impetus, has a variety of applications, including drug delivery and flexible electronics. In this work, we study the growth of polystyrene pillars in the electric field for different combinations of annealing temperature, film thickness, and electrode separation (electric field intensity). There are five stages for the growth of the polystyrene pillars for all the configurations used in this work, including a nucleation stage, a linear growth stage, an acceleration stage in the pillar length prior to the contact between the top surface of a pillar and the upper electrode, a radial growth stage after the contact, and a stationary stage without further growth of the pillar. In the linear growth stage, there exist linear relationships between the pillar length and the annealing time and between the square of the pillar diameter and the annealing time. The activation energies for the rate processes controlling the radial growth and the length growth in the linear growth stage are 30.2 and 25.3 kJ/mol, respectively. There are two rate processes controlling the radial growth of the pillars: one is the field-induced flow of polymer through the polymer film to the roots of pillars and the other is the coalescence of pillars. The activation energy for the coalescence is 16.5 kJ/mol. The results obtained in this work offer a practical route to control the geometrical dimensions of polymer pillars through the processing parameters.

Hierarchical Nanoparticle Assemblies Formed via One-Step Catalytic Stamp Pattern Transfer

The one-step catalytic stamp pattern transfer process is described for producing arrays of hierarchical nanoparticle assemblies. The method simply combines in situ nanoparticle synthesis triggered by free residual Si-H groups on PDMS stamps and the lift-off pattern transfer technique. No additional nanoparticle synthesis procedure is required before the pattern transfer process. Exquisitely uniform and precisely spaced hierarchical nanoparticle assemblies with designed geometry can be rapidly produced using the catalytic stamp pattern transfer process. Sequential catalytic stamp pattern transfer also is described to generate multilayered, hierarchical nanoparticle assemblies with various geometries. The hierarchical nanoparticle assemblies catalytically transferred onto the surface are not just nanoparticles but nanoparticle-polydimethylsiloxane residue composites. The in situ-synthesized nanoparticles retain optical properties. The hierarchical nanoparticle assemblies with precisely controlled geometry further show potential in the application of surface-enhanced Raman scattering. The capability of one-step catalytic stamp pattern transfer allows the scalable and reproducible fabrication of well-defined hierarchical nanoparticle assemblies.

Mesoscopic simulation study on the structural transition of comb-shaped block copolymer lamellae on chemically patterned substrates: from vertical to lateral

Directed self-assembly of polymers on chemically homogeneous and heterogeneous patterns is of considerable interest for nanolithography and nanofluidic devices. By employing dissipative particle dynamics (DPD) technology, we explore the nanoscale phase separation of comb-like block copolymers (CBCPs) confined at chemically homogeneous and heterogeneous substrates. Herein, the geometric and energetic influences of striped substrates on the microphases are firstly studied using various geometries of annular stripes for the heterogeneous substrates. Different parameters including the stripe geometry, substrate selectivity, and film thickness are studied systematically. T-Junction lamellae and acclivitous alignment are achieved on the heterogeneous substrates because of the synergy of geometrical effects of the striped pattern from heterogeneous substrates together with weak preference of the substrates toward one of the CBCP components. In this study, we provide a detailed understanding of microphase separation of CBCPs on the heterogeneous substrates, and the approach outlined in the present study offers a crucial tool for experimentalists to design CBCP thin films with complex device-oriented structures.

Controlled Nanoscale Electrohydrodynamic Patterning Using Mesopatterned Template

We report the path for a possible fabrication of an array of nanogrooves, by electro-hydrodynamic instability-mediated patterning of a thin polymer film using a patterned stamp with much larger features. Using a predictive computational model based on finite element method, we find the route to control the coalescence of initial instabilities that arise with the onset of spatially varying DC electric field generated through topographical patterns in the top electrode. These quasi-steady structures are shown to evolve with the electrostatic and geometric nature of the two-electrode system and are of a stable intermediate during the process of feature replication, under each electrode feature. We identify conditions to obtain nanogrooves for a range of operating conditions. Such simulations are likely to guide experiments, where simultaneous optimization of multiple parameters to fabricate features with lateral dimension smaller than that of the electrode patterns is challenging.

Laser patterning of transparent polymers assisted by plasmon excitation

Plasmon-assisted lithography of thin transparent polymer films, based on polymer mass-redistribution under plasmon excitation, is presented. The plasmon-supported structures were prepared by thermal annealing of thin Ag films sputtered on glass or glass/graphene substrates. Thin films of polymethylmethacrylate, polystyrene and polylactic acid were then spin-coated on the created plasmon-supported structures. Subsequent laser beam writing, at the wavelength corresponding to the position of plasmon absorption, leads to mass redistribution and patterning of the thin polymer films. The prepared structures were characterized using UV-Vis spectroscopy and confocal and AFM microscopy. The shape of the prepared structures was found to be strongly dependent on the substrate type. The mechanism leading to polymer patterning was examined and attributed to the plasmon-heating. The proposed method makes it possible to create different patterns in polymer films without the need for wet technological stages, powerful light sources or a change in the polymer optical properties.

Designing 3D Biological Surfaces via the Breath-Figure Method

The fabrication of biointerfaces that mimic cellular physiological environments is critical to understanding cell behaviors in vitro and for the design of tissue engineering. Breath figure is a self-assemble method that uses water droplets condensed from moisture as template and ends up with a highly ordered hexagonal pore array; this approach is used to fabricate various biological substrates. This progress report provides an overview of strategies to achieve topographical modifications and chemical-patterned arrays, such as modulation of the pore size, shape and selective decoration of the honeycomb holes. Using recent results in the biological fields, potential future applications and developments of honeycomb structures are commented upon.

Evolution of Surface Nanopores in Pressurised Gyrospun Polymeric Microfibers

The selection of a solvent or solvent system and the ensuing polymer–solvent interactions are crucial factors affecting the preparation of fibers with multiple morphologies. A range of poly(methylmethacrylate) fibers were prepared by pressurised gyration using acetone, chloroform, N,N-dimethylformamide (DMF), ethyl acetate and dichloromethane as solvents. It was found that microscale fibers with surface nanopores were formed when using chloroform, ethyl acetate and dichloromethane and poreless fibers were formed when using acetone and DMF as the solvent. These observations are explained on the basis of the physical properties of the solvents and mechanisms of pore formation. The formation of porous fibers is caused by many solvent properties such as volatility, solubility parameters, vapour pressure and surface tension. Cross-sectional images show that the nanopores are only on the surface of the fibers and they were not inter-connected. Further, the results show that fibers with desired nanopores (40–400 nm) can be prepared by carefully selecting the solvent and applied pressure in the gyration process.

Wrinkling and Folding on Patched Elastic Surfaces: Modulation of the Chemistry and Pattern Size of Microwrinkled Surfaces

An unconventional strategy is proposed that takes advantage of localized high-deformation areas, referred to as folded wrinkles, to produce microstructured elastic surfaces with precisely controlled pattern dimensions and chemical distribution. For that purpose, elastic PDMS substrates were prestretched to a different extent and oxidized in particular areas using a mask. When the stretching was removed, the PDMS substrate exhibited out-of-plane deformations that largely depend on the applied prestretching. Prestretchings below 100% lead to affine deformations in which the treated areas are buckled. On the contrary, prestretchings above ε >100% prior to surface treatment induce the formation of folded wrinkles on those micrometer-size ultraviolet-ozone (UVO) treated areas upon relaxation. As a result, dual periodic wrinkles were formed due to the alternation of highly deformed (folded) and low deformed (buckled) areas. Our strategy is based on the surface treatment at precise positions upon prestretching of the elastic substrate (PDMS). Additionally, this approach can be used to template the formation of wrinkled surfaces by alternating lines of folded wrinkles (valleys) and low-deformed areas (hills). This effect allowed us to precisely tune the shape and distribution of the UVO exposed areas by varying the prestretching direction. Moreover, the wrinkle characteristics, including period and amplitude, exhibit a direct relation to the dimensions of the patterns present in the mask.

Investigation of the role of template features on the electrically induced structure formation (EISF) for a faithful duplication

Electrically induced structure formation, as a physical approach to fabricate micro/nanostructures, has attracted much attention because of the simple process, low-cost, high-efficiency, and wide applications on electronics, microfluidics, and so forth. Hitherto, the influence of some process parameters, such as voltage, air gap, film thickness, polymer properties, on the polymeric behavior, and the structure formation has been explored, neglecting the effects of the template features, which affect the polymer deformation. Especially for the conductive protrusions directly contacting the polymer, the phenomenon of electric breakdown may occur, leading to a failure of structure formation. The limitation of the research on the template features triggers the necessity to study its influence for a faithful deformation. In this paper, three types of patterned template are studied based on the electric field at the air-polymer interface, consisting of completely conductive template, partially conductive template, and dielectric template. Comprehensive consideration of the electric intensity for a sufficient driving pressure and the leaky current for preventing damaging the polymer, some guiding opinions on the template material and geometry can be provided to design the patterned template for the electrically induced structure formation process with a purpose for a faithful structure.

Bioinspired Hierarchically Structured Surfaces for Efficient Capture and Release of Circulating Tumor Cells

The development of novel bioinspired surfaces with hierarchical micro- and nanoscale topographic structures for efficient capture and release of circulating tumor cells (CTCs) is reported. The capture of CTCs, facilitated by surface-immobilized epithelial cell adhesion molecule antibodies (anti-EpCAM), was shown to be significantly enhanced in novel three-dimensional hierarchically structured surfaces that were fabricated by replicating the natural micro- and nanostructures of rose petals. Under static conditions, these hierarchical capture substrates exhibited up to 6 times higher cell capture ability at concentrations of 100 cells mL^-1 in contrast to flat anti-EpCAM-functionalized polydimethylsiloxane (PDMS) surfaces. As indicated by scanning electron microscopy (SEM) and immunofluorescent images, this enhancement can be in large part attributed to the topographical interaction between nanoscale cell surface components and nanostructures on the substrate. Similarly, the increased surface area affords a higher nominal coverage of anti-EpCAM, which increases the number of available binding sites for cell capture. By treating the substrates with the biocompatible reductant glutathione (GSH), up to 85% of the captured cells were released, which displayed over 98% cell viability after culturing on tissue culture polystyrene (TCP) for 24 h. Therefore, these bioinspired hierarchically structured and functionalized substrates can be successfully applied to capture CTCs, as well as release CTCs for subsequent analysis. These findings provide new prospects for designing cell-material interfaces for advanced cell-based biomedical studies in the future.

Recent advances in liquid mixtures in electric fields

When immiscible liquids are subject to electric fields interfacial forces arise due to a difference in the permittivity or the conductance of the liquids, and these forces lead to shape change in droplets or to interfacial instabilities. In this topical review we discuss recent advances in the theory and experiments of liquids in electric fields with an emphasis on liquids which are initially miscible and demix under the influence of an external field. In purely dielectric liquids demixing occurs if the electrode geometry leads to sufficiently large field gradients. In polar liquids field gradients are prevalent due to screening by dissociated ions irrespective of the electrode geometry. We examine the conditions for these 'electro prewetting' transitions and highlight few possible systems where they might be important, such as in stabilization of colloids and in gating of pores in membranes.

Numerical study of the faithful replication of micro/nanostructures on curved surfaces by the electrohydrodynamic instability process

This paper reports the numerical study of the one-step faithful replication of micro/nano-scale structures on a fiber surface by using the electrohydrodynamic instability patterning (EHDIP) process. By employing a rigorous numerical analysis method, conditions are revealed under which the faithful replication of a pattern can be achieved from a curved master electrode. It is found that the radius of curvature of the fiber plays an important role in determining the final morphology of the pattern when the destabilizing electric field is dominant in both the flat and patterned template cases. In general, stronger electric fields and larger radii of curvature of the substrate are favorable for the faithful replication of the pattern. In addition, theoretical analysis shows that higher aspect ratio of micro/nanostructures can be obtained on curved surfaces by using a master with a much lower aspect ratio. The results demonstrated in this study aims to provide guidelines for the faithful fabrication of micro/nanostructures on curved surfaces by the EHDIP process.

Capillary Leveling of Freestanding Liquid Nanofilms

We report on the capillary-driven leveling of a topographical perturbation at the surface of a freestanding liquid nanofilm. The width of a stepped surface profile is found to evolve as the square root of time. The hydrodynamic model is in excellent agreement with the experimental data. In addition to exhibiting an analogy with diffusive processes, this novel system serves as a precise nanoprobe for the rheology of liquids at interfaces in a configuration that avoids substrate effects.

Dynamic response of a thin sessile drop of conductive liquid to an abruptly applied or removed electric field

We consider, both theoretically and experimentally, a thin sessile drop of conductive liquid that rests on the lower plate of a parallel-plate capacitor. We derive analytical expressions for both the initial deformation and the relaxation dynamics of the drop as the electric field is either abruptly applied or abruptly removed, as functions of the geometrical, electrical, and material parameters, and investigate the ranges of validity of these expressions by comparison with full numerical simulations. These expressions provide a reasonable description of the experimentally measured dynamic response of a drop of conductive ionic liquid 1-butyl-3-methyl imidazolium tetrafluoroborate.

Deformation Hysteresis of Electrohydrodynamic Patterning on a Thin Polymer Film

Electrohydrodynamic patterning is a technique that enables micro/nanostructures via imposing an external voltage on thin polymer films. In this investigation, we studied the electrohydrodynamic patterning theoretically and experimentally, with special interest focused on the equilibrium state. It is found that the equilibrium structure height increases with the voltage. In addition, we have observed, and believe it to be the first time, a hysteresis phenomenon exists in the relationship between the voltage and structure height. With an increase in the voltage, a critical value (the first critical voltage) is noticed, above which the polymer film would increase dramatically until it comes into contact with the template. However, with a decrease in the voltage, a smaller voltage (the second critical voltage) is needed to detach the polymer from the template. The mismatch of the first and second critical voltages distorts the voltage-structure height curve into an "S" shape. Such a phenomenon is verified for three representative templates and also by experiments. Furthermore, the effects of some parameters (e.g., polymer film thickness and dielectric constant) on this hysteresis phenomenon are also discussed.

Thermo-Electrohydrodynamic Patterning in Nanofilms

To improve the electrically assisted patterning process and create smaller sized features with the higher active surface area, the combined thermocapillary-electrohydrodynamic (TC-EHD) instability of liquid nanofilms is considered. First, the 3-D thin film equation is rederived for nonisothermal films and then the influential factors on the dynamics and stability of thin liquid film are found using linear stability (LS) analysis. Nonlinear studies are also conducted to investigate the long-time evolution of the interface using an in-house developed Fortran code employing high order finite difference and adaptive time step solver for the spatial and time derivatives. The number density of pillars (columnar raised structure) formed in 1 μm(2) area is significantly increased compared to the EHD base-case and nanosized pillars are created due to the thermocapillary effects. Relative interface area increases of up to 18% due to this pattern miniaturization are realized. It is also found that increase in the thermal conductivity ratio of layers changes the mechanism of pattern formation resulting in nonuniform and randomly distributed micro pillars being generated.

Electric-Field-Induced Nanoscale Surface Patterning in Mexylaminotriazine-Functionalized Molecular Glass Derivatives

Nanoscale surface patterns were observed in thin films of mexylaminotriazine-functionalized glasses containing polar groups upon the application of an electric field at temperatures over their glass transition temperatures (Tg). This phenomenon occurred due to the surface deformation process initiated by external electric field instabilities on the films. The minimal surface deformation temperature (Tdewet) relative to Tg was found to increase as a function of the polarity of the substituents and the surface pattern roughness was observed to increase linearly with temperature for a fixed electric field and exposure time. Reversal of the electrical field polarity and the use of both hydrophilic and hydrophobic substrates did not significantly change the surface deformation behavior of the films, which is due to the deposition of charges at the free interface. The application of a mask between the electric field electrodes allowed to selectively pattern areas that are exposed. Furthermore, it was observed that this surface deformation behavior was reversible, since heating the films to a temperature above Tg in the absence of an electric field caused the erasure of all surface patterns.

Tunable Nanopatterning of Conductive Polymers via Electrohydrodynamic Lithography

An increasing number of technologies require the fabrication of conductive structures on a broad range of scales and over large areas. Here, we introduce advanced yet simple electrohydrodynamic lithography (EHL) for patterning conductive polymers directly on a substrate with high fidelity. We illustrate the generality of this robust, low-cost method by structuring thin polypyrrole films via electric-field-induced instabilities, yielding well-defined conductive structures with feature sizes ranging from tens of micrometers to hundreds of nanometers. Exploitation of a conductive polymer induces free charge suppression of the field in the polymer film, paving the way for accessing scale sizes in the low submicron range. We show the feasibility of the polypyrrole-based structures for field-effect transistor devices. Controlled EHL pattering of conductive polymer structures at the micro and nano scale demonstrated in this study combined with the possibility of effectively tuning the dimensions of the tailor-made architectures might herald a route toward various submicron device applications in supercapacitors, photovoltaics, sensors, and electronic displays.

Influence of electrode types on the electrohydrodynamic instability patterning process: a comparative study

A polymer film resting on a planar substrate under the influence of a electric field. (A) A conductive patterned electrode. (B) A conductive pattern on a dielectric substrate.

Instability, self-organization and pattern formation in thin soft films

The free surface of a thin soft polymer film is often found to become unstable and self-organizes into various meso-scale structures. In this article we classify the instability of a thin polymer film into three broad categories, which are: category 1: instability of an ultra-thin (<100 nm) viscous film engendered by amplification of thermally excited surface capillary waves due to interfacial dispersive van der Waals forces; category 2: instability arising from the attractive inter-surface interactions between the free surface of a soft film exhibiting room temperature elasticity and another rigid surface in its contact proximity; and category 3: instability caused by an externally applied field such as an electric field or a thermal gradient, observed in both viscous and elastic films. We review the salient features of each instability class and highlight how characteristic length scales, feature morphologies, evolution pathways, etc. depend on initial properties such as film thickness, visco-elasticity (rheology), residual stress, and film preparation conditions. We emphasize various possible strategies for aligning and ordering of the otherwise isotropic structures by combining the essential concepts of bottom-up and top-down approaches. A perspective, including a possible future direction of research, novelty and limitations of the methods, particularly in comparison to the existing patterning techniques, is also presented for each setting.

Hierarchical periodic micro/nano-structures on nitinol and their influence on oriented endothelialization and anti-thrombosis

The applications of hierarchical micro/nano-structures, which possess properties of two-scale roughness, have been studied in various fields. In this study, hierarchical periodic micro/nano-structures were fabricated on nitinol, an equiatomic Ni-Ti alloy, using a femtosecond laser for the surface modification of intravascular stents. By controlling the laser fluence, two types of surfaces were developed: periodic nano- and micro/nano-structures. Evaluation of water contact angles indicated that the nano-surface was hydrophilic and the micro/nano-surface was hydrophobic. Endothelial cells aligned along the nano-structures on both surfaces, whereas platelets failed to adhere to the micro/nano-surface. Decorrelation between the responses of the two cell types and the results of water contact angle analysis were a result of the pinning effect. This is the first study to show the applicability of hierarchical periodic micro/nano-structures for surface modification of nitinol.

Solid particles adsorbed on capillary-bridge-shaped fluid polystyrene surfaces

Particles adsorbed on microscopic polystyrene (PS) capillary bridge surfaces were observed to investigate their motion under capillary forces arising from a nonuniform shape. Capillary bridges were created by placing thin PS films, heated above the glass transition temperature (Tg), between two electrodes with an air gap between the surface of the PS and the upper electrode. Silica particles, 100 nm in diameter, were placed on the surface of the PS capillary bridges, and the sample was heated above the Tg of PS to enable particle motion. Samples were cooled to below Tg, and the locations of the particles were observed using scanning electron microscopy. The particles did not preferentially locate around the center of the capillary bridge, as predicted by others, but instead segregated to the edges. These results indicate that the forces driving particles to the three-phase contact line (air/PS/electrode surface) are greater than those locating particles around the center.

Directional Superficial Photofluidization for Deterministic Shaping of Complex 3D Architectures

The fabrication of micro- and nanostructures is one of the cornerstones of current materials science and technology. There is a strong interest in processing methods capable of manufacturing engineered complex structures on a large area. A method that is gaining a growing attention in this context is based on surface reshaping of photosensitive materials, such as certain azobenzene derivatives by way of a process of light-induced mass migration, also described as "athermal photofluidization". Here, we apply this method to prestructured substrate, converting simple periodic structures initially patterned only in two dimensions into complex-shaped three-dimensional (3D) structures by a single processing step over a large area. The optical variables of the irradiating beam are used to gain unprecedented deterministic control on the resulting 3D architectures. We also provide some initial demonstrations of the potential application of this novel shaping method, including unidirectional wetting surfaces and micro- and nanoscaled fluidic channel manufactured with it.

Hysteretic DC electrowetting by field-induced nano-structurations on polystyrene films

Electrowetting (EW) offers executive wetting control of conductive liquids on several polymer surfaces. We report a peculiar electrowetting response for aqueous drops on a polystyrene (PS) dielectric surface in the presence of silicone oil. After the first direct current (DC) voltage cycle, the droplet failed to regain Young's angle, yielding contact angle hysteresis, which is close to a value found in ambient air. We conjecture that the hysteretic EW response appears from in situ surface modification using electric field induced water-ion contact with PS surface inducing nano-structuration by electro-hydrodynamic (EHD) instability. Atomic force microscopy confirms the formation of nano-structuration on the electrowetted surface. The effects of molecular weight, applied electric field, water conductivity and pH on nano-structuration are studied. Finally, the EW based nano-structuration on PS surface is used for the enhanced loading of aqueous dyes on hydrophobic surfaces.