We demonstrate the replication of nanosized pillars in polymer (cyclic olefin copolymer) by injection molding using nanostructured thermally cured hydrogen silsesquioxane (HSQ) ceramic coatings on stainless steel mold inserts with mold nanostructures produced by a simple embossing process. At isothermal mold conditions, the average pillar height increases by up to 100% and a more uniform height distribution is observed compared to a traditional metal mold insert. Thermal heat transfer simulations predict that the HSQ film retards the cooling of the polymer melt during the initial stages of replication, thus allowing more time to fill the nanoscale cavities compared to standard metal molds. A monolayer of a fluorinated silane (heptadecafluorotrichlorosilane) deposited on the mold surface reduces the mold/polymer interfacial energy to support demolding of the polymer replica. The mechanical stability of thermally cured HSQ makes it a promising material for nanopattern replication on an industrial scale without the need for slow and energy intensive variotherm processes.

Through evolution, nature has optimised structures and materials with a hierarchy from the macro-to the nanoscale. Biological materials are very sophisticated in the way they solve challenges associated with life. Some properties of commercial interest found in nature are selfcleaning, aerodynamic lift, anti-adhesion, water harvesting, water-floating and staying dry. Biomimetics, to learn from nature, has been used for centuries to create new innovative devices. With the use of "nanotools", it is possible to design hierarchical surface structures with exceptional functional properties. In this paper, an overview of interesting surface properties with biomimetic potential, strategies for nanomanipulation of surfaces, potential industrial applications and the potential of using atomistic modelling to optimise surface structuring are discussed.

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We demonstrate the transfer and immobilization of active antibodies from a low surface- energy mold surface to thermoplastic replica surfaces using injection molding, and we investigate the process at molecular scale. The transfer process is highly efficient, as verified by atomic force microscopy (AFM) and X-ray photoelectron spectroscopy (XPS) of the mold and replica surfaces. AFM analysis reveals partial nanometer-scale embedding of the protein into the polymer matrix as a possible mechanism of permanent immobilization. Replicas with rabbit anti-mouse IgG immobilized as capture antibody at the hot polymer melt surface during injection molding show similar affinity for their antigen (mouse IgG) in sandwich enzyme-linked immunosorbent assay (ELISA) as capture antibodies deposited by passive adsorption onto a bare thermoplastic replica. The transferred antibodies retain their functionality after incubation in serum-containing cell medium for >1 week. A mold coating time of 10 min prior to injection molding is sufficient for producing highly sensitive ELISA assays, thus enabling the short processing cycle times required for mass production of single-use biodevices relying on active immobilized antibodies.