We describe a new fabrication process utilizing polydimethylesiloxane (PDMS) as a sacrificial substrate layer for fabricating free-standing SU-8-based biomedical and microfluidic devices. The PDMS-on-glass substrate permits SU-8 photo patterning and layer-to-layer bonding. We have developed a novel PDMS-based process which allows the SU-8 structures to be easily peeled off from the substrate after complete fabrication. As an example, a fully enclosed microfluidic chip has been successfully fabricated utilizing the presented new process. The enclosed microfluidic chip uses adhesive bonding technology and the SU-8 layers from 10 µm to 450 µm thick for fully enclosed microchannels. SU-8 layers as large as the glass substrate are successfully fabricated and peeled off from the PDMS layer as single continuous sheets. The fabrication results are supported by optical microscopy and profilometry. The peel-off force for the 120 µm thick SU-8-based chips is measured using a voice coil actuator (VCA). As an additional benefit the release step leaves the input and the output of the microchannels accessible to the outside world facilitating interconnecting to the external devices.

A new fabrication technology utilizing SU-8 as a sacrificial mask for metallization of the PDMS surface is presented. The sacrificial SU-8 layer process offers superior performance for reliable and repeatable metallization on the PDMS layer. Sacrificial SU-8 masks from 45 µm to 250 µm thickness are successfully fabricated on the PDMS layer to pattern gold on the PDMS surface. These layers are successfully peeled off from the PDMS surface after a metal deposition step. Metal lines from 10 µm to 500 µm wide and 1 mm to 50 mm long are successfully patterned and tested. Furthermore, the sacrificial SU-8 mask can be removed within minutes to realize metal patterns on the PDMS surface and does not leave any residue after removal of the SU-8 layer. As this new process is intended for use in fabrication of microfluidic and biomedical microdevices, electrodes of an electro-enzymatic glucose sensor are presented to demonstrate the technology.

Inkjet printing of silver ink has been widely used to print conductive patterns in flexible electronic devices, and the printed patterns are commonly known to be colorless. We demonstrate that by printing a single type of ordinary silver nanoparticle ink on top of a substrate patterned with polymer nanostructures, the printed silver is molded by the nanostructures and gains robust structural colors. The colors are tunable by varying the geometries of nanostructures, and a broad range of visual colors can be achieved by mixing the red, green, and blue colors displayed from silver dots printed on different nanostructures. Such mechanism can enable full-color, scalable, high-throughput, versatile, and cost-effective printing of structural color images for regular publishing and displaying purposes. In experiments, we implemented a transparent polymer substrate patterned with diffractive nanostructure arrays to print full-color images. The printed images display color-shifting optically variable effects useful for security and authentication applications that demand customizable anticounterfeiting features.

Recently, our group demonstrated an inkjet-based technique to enable high-throughput, versatile and full-colour printing of structural colours on generic pixelated nanostructures, termed as molded ink on nanostructured surfaces. The printed colours are controlled by the area of printed silver on the pixelated red, green and blue polymer nanostructure arrays. This paper investigates the behaviour of jetted silver ink droplets on nanostructured surfaces and the microscale dot patterns implemented during printing process, for achieving accurate and consistent colours in the printed images. The surface wettability and the schemes of filling silver dots inside the subpixels are crucial to the quality of printed images. Several related concepts and definitions are introduced, such as filling ratio, full dots per subpixel (DPSP), number of printable colours, colour leaking and dot merging. In our experiments, we first chemically modified the surface to control the wettability and dot size. From each type of modified surface, various filling schemes were experimented and the printed results were evaluated with comprehensive considerations on the number of printable colours and the negative effects of colour leaking and dot merging. Rational selection of the best filling scheme resulted in a 2-line filling scheme using 20 μm dot spacing and line spacing capable of printing 9261 different colours with 121 pixel per inch display resolution, on low-wettability surface. This study is of vital importance for scaling up the printing technique in industrial applications and provides meaningful insights for inkjet-printing on nanostructures.

Abbreviations: (Ag/AgCl) silver/silver chloride, (3-D) three-dimensional, (GOx) glucose oxidase, (PDMS) poly dimethylsiloxane