Replica
molding is one of the most common and low-cost methods
for constructing microstructures for various applications, including
dry adhesives, optics, tissue engineering, and strain sensors. However,
replica molding provides only a single-height microstructure from
a mold and master molds produced by an expensive photolithography
process are required to prepare microstructures with different heights.
Herein, we present a strategy to control the height of micropillars
from the same mold by varying the cavity size of the micromold and
the viscosity of the photocurable polyimide resin. The height of the
constructed micropillar decreases in the case of small microcavities
or high viscosity resin. In addition, the height of the micropillar
arrays could be arbitrarily patterned by applying a masking technique.
We believe that this cost-effective technique can be applied to metasurfaces
for manipulation of electromagnetic signal or in biomedical applications
including cell-culture and stem-cell differentiation.