High Density Array Matrices of Polymeric Structures by Ultrathin Interfacial Layer-Mediated Double Replication Approach

Abstract

We demonstrate here rapid, efficient and reliable fabrication and replication of high density arrays of polymeric structures using ultrathin layer-mediated processes. Highly uniform polymeric structures with submicrometer to nanometer radius-of-curvatures and consistent vertical profiles could be achieved via sequential replication cycles. Highly controllable dry surface treatment has been used to create a chemically inert and stable interfacial zone between two polymers of the same chemical identities to allow simple replica molding and rapid intact release of highly flexible molded polymeric structures. The approach could, in principle, be extended to other systems with appropriate modification of interfacial surface properties.