Micropillar Arrays Research Articles

An electrochemiluminescent magneto-immunosensor for ultrasensitive detection of hs-cTnI on a microfluidic chip

Sensitive detection and precise quantitation of trace-level crucial biomarkers in a complex sample matrix has become an important area of research. For example, the detection of high-sensitivity cardiac troponin I (hs-cTnI) is strongly recommended in clinical guidelines for early diagnosis of acute myocardial infarction. Based on the use of an electrode modified by single-walled carbon nanotubes (SWCNTs) and a Ru(bpy)32+-doped silica nanoparticle (Ru@SiO2)/tripropylamine (TPA) system, a novel type of electrochemiluminescent (ECL) magneto-immunosensor is developed for ultrasensitive detection of hs-cTnI. In this approach, a large amount of [Ru(bpy)3]2+ is loaded in SiO2 (silica nanoparticles) as luminophores with high luminescent efficiency and SWCNTs as electrode surface modification material with excellent electrooxidation ability for TPA. Subsequently, a hierarchical micropillar array of microstructures is fabricated with a magnet placed at each end to efficiently confine a single layer of immunomagnetic microbeads on the surface of the electrode and enable 7.5-fold signal enhancement. In particular, the use of transparent SWCNTs to modify a transparent ITO electrode provides a two-order-of-magnitude ECL signal amplification. A good linear calibration curve is developed for hs-cTnI concentrations over a wide range from 10 fg/ml to 10 ng/ml, with the limit of detection calculated as 8.720 fg/ml (S/N = 3). This ultrasensitive immunosensor exhibits superior detection performance with remarkable stability, reproducibility, and selectivity. Satisfactory recoveries are obtained in the detection of hs-cTnI in human serum, providing a potential analysis protocol for clinical applications.

Enhanced marine biofouling and corrosion resistance through springtails-inspired papillate-like micropillar arrays surface modified by antimicrobial peptide

Marine biological fouling has a serious impact on artificial facilities, and traditional antifouling coatings are not beneficial to green development, which lead to the urgent to develop green strategies that can effectively prevent fouling. In this study, an innovative confluence of physical and biological approaches was employed to mitigate the harm caused by biofouling on a material substrate. Firstly, a hierarchical microstructured morphology was prepared on an aluminum surface by reactive ion etching and characterised. The antibacterial peptide, A-2S, was surface modified with dopamine as a coupling agent to produce a physico-biological synergistic antifouling surface. X-ray photoelectron spectroscopy, fourier transform infrared spectroscopy, and electrochemical experiments were then used to analyse the binding effect and corrosion resistance performance. A-2S was successfully modified on the sample surface and exhibited good corrosion resistance with a corrosion inhibition efficiency of 86.57 %. Compared to a bare aluminum plate, the microstructure surface has a certain inhibitory effect on fouling organisms, and the antifouling performance decreases over time. In contrast, the antimicrobial peptide synergistic surfaces demonstrated superior durable antifouling performance. Compared with the 50 % of the antifouling performance on the microstructure surface, the synergistic surface has a unique contact point effect of the microstructure and excellent antibacterial and bactericidal properties of antimicrobial peptides, resulting in a surface antifouling performance of over 80 %. The synergistic modification method enhanced the corrosion resistance of the material and reduced the adhesion of fouling organisms, mitigating the harm caused by biofouling on the marine equipment substrate.

Enhanced light absorption in high-quality three-dimensional Sb2S3 micropillar arrays based on template-assisted growth

Sb2S3 has garnered significant attention in photovoltaic applications due to its suitable bandgap, single stable orthogonal phase and excellent stability. However, due to the coexistence of indirect transition parts in the bandgap, a thicker Sb2S3 absorption layer is usually required to achieve decent light absorption in solar cells, which inevitably leads to an increase in trapped states in the bulk. Therefore, it is of great importance to realize more photogenerated carriers without increasing charge recombination. Here, we realized the in-situ growth of high-quality Sb2S3 micropillar arrays on the template prepared by laser direct writing. Compared with the traditional thick layer, this array structure with less material usage can not only achieve more light absorption by enhancing photon scattering, but also optimize carrier transport at the interface by expanding their contact area with the hole transporting layer. This work provides a strategy for controllably achieving enhanced light absorption of Sb2S3 structures, which is a perspective for the improvement of highly efficient solar cells.

Rapid Surface Charge Mapping Based on a Liquid Crystal Microchip.

Rapid surface charge mapping of a solid surface remains a challenge. In this study, we present a novel microchip based on liquid crystals for assessing the surface charge distribution of a planar or soft surface. This chip enables rapid measurements of the local surface charge distribution of a charged surface. The chip consists of a micropillar array fabricated on a transparent indium tin oxide substrate, while the liquid crystal is used to fill in the gaps between the micropillar structures. When an object is placed on top of the chip, the local surface charge (or zeta potential) influences the orientation of the liquid crystal molecules, resulting in changes in the magnitude of transmitted light. By measuring the intensity of the transmitted light, the distribution of the surface charge can be accurately quantified. We calibrated the chip in a three-electrode configuration and demonstrated the validity of the chip for rapid surface charge mapping using a borosilicate glass slide. This chip offers noninvasive, rapid mapping of surface charges on charged surfaces, with no need for physical or chemical modifications, and has broad potential applications in biomedical research and advanced material design.

HLM chip – A microfluidic approach to study the mechanistic basis of cytochrome P450 inhibition using immobilized human liver microsomes

Cytochrome P450 (CYP) system is a critical elimination route to most pharmaceuticals in human, but also prone to drug-drug interactions arising from the fact that concomitantly administered pharmaceuticals inhibit one another's CYP metabolism. The most severe form of CYP interactions is irreversible inhibition, which results in permanent inactivation of the critical CYP pathway and is only restored by de novo synthesis of new functional enzymes. In this study, we conceptualize a microfluidic approach to mechanistic CYP inhibition studies using human liver microsomes (HLMs) immobilized onto the walls of a polymer micropillar array. We evaluated the feasibility of these HLM chips for CYP inhibition studies by establishing the stability and the enzyme kinetics for a CYP2C9 model reaction under microfluidic flow and determining the half-maximal inhibitory concentrations (IC50) of three human CYP2C9 inhibitors (sulfaphenazole, tienilic acid, miconazole), including evaluation of their inhibition mechanisms and nonspecific microsomal binding on chip. Overall, the enzyme kinetics of CYP2C9 metabolism on the HLM chip (KM = 127 ± 55 µM) was shown to be similar to that of static HLM incubations (KM = 114 ± 14 µM) and the IC50 values toward CYP2C9 derived from the microfluidic assays (sulfaphenazole 0.38 ± 0.09 µM, tienilic acid 3.4 ± 0.6 µM, miconazole 0.54 ± 0.09 µM) correlated well with those determined using current standard IC50 shift assays. Most importantly, the HLM chip could distinguish between reversible (sulfaphenazole) and irreversible (tienilic acid) enzyme inhibitors in a single, automated experiment, indicating the great potential of the HLM chip to simplify current workflows used in mechanistic CYP inhibition studies. Furthermore, the results suggest that the HLM chip can also identify irreversible enzyme inhibitors, which are not necessarily resulting in a time-dependent inhibition (like suicide inhibitors), but whose inhibition mechanism is based on other kind of covalent or irreversible interaction with the CYP system. With our HLM chip approach, we could identify miconazole as such a compound that nonselectively inhibits the human CYP system with a prolonged, possibly irreversible impact in vitro, even if it is not a time-dependent inhibitor according to the IC50 shift assay.

Two‐Photon Direct Laser Writing of pNIPAM Actuators in Microchannels for Dynamic Microfluidics

Microfluidic tools enable to investigate and manipulate various chemical and biological processes at small scales. As a result, it finds widespread applications in lab‐on‐chip devices, drug delivery systems, or miniaturized cell cultures. However, microfluidic devices are still limited in their flexibility and are often designed to fulfill a single functionality. Moreover, technologies to introduce dynamic functionalities with high precision and at high resolution after the development of a continuous phase microfluidic chip remain scarce. Herein, two‐photon polymerization direct laser writing is introduced as a suitable approach to equip continuous phase microfluidic chips with structurally defined thermoresponsive poly(N‐isopropyl‐acrylamide) (pNIPAM) microactuators. Harnessing the lower critical phase transition temperature of pNIPAM, and upon controlling specific design parameters, the efficient catch and release of polystyrene beads of different sizes using a pNIPAM micropillar brush array is demonstrated. Moreover, a biocompatible pNIPAM microgripper array is designed to subsequently capture and release differently sized (single) cell populations. Overall, the method offers great flexibility and a high degree of freedom toward the fabrication of dynamic microfluidic devices with great adaptability to experimental conditions in real time.

Impact of Ceramic Micropillar Array and Fiber Layer Composite Structure on Kinematic and Heat Transfer Characteristics of Single Droplet Impacting a Wall.

The well-known limitations of spray cooling on high-temperature solids at the Leidenfrost temperature point have been significantly improved by a composite structure of steel micropillar arrays and insulating thin films. However, the physical mechanism of a single droplet impact on the walls of high-temperature composite structures in spray cooling remains elusive. We have experimentally studied and quantified the kinematic and thermal transfer characteristics of a single droplet impacting high-temperature micropillar arrays with fiber membrane composite structures. In particular, micropillar arrays of ceramic materials of different shapes (rectangular and cylindrical) used in this study were made using the more flexible PμSL technique, for which precision reaches the micron level. The results show that the presence and different layouts (embedded or placed on top) of the fiber layer significantly affect the spreading coefficient and thermal transfer efficiency of the droplets after impact. In terms of kinematic characteristics, unrelated to the structure of micropillar arrays, compared to structures without film, the maximum spreading coefficient of droplets significantly increased by more than 40% (43% for rectangular, 46% for cylindrical) when the fiber film was placed on top, and increased by more than 20% (20% for rectangular, 33% for cylindrical) when the fiber film was embedded. In terms of thermal transfer characteristics, at a temperature of 200 °C, the presence of the fiber layer changed the wettability of the surface of the micropillar structure, leading to a certain extension of the total evaporation time of the droplets compared to the surface of the micropillar structure without film.

Mathematical modeling of an electrostatic MEMS with tilted elastomeric micro-pillars

The aim of this study is to develop a comprehensive mathematical model for an electrostatic MEMS (Micro-Electro-Mechanical Systems) with gap-filling tilted micro-pillars. Elastomeric pillars are used due to their high dielectric constant, resulting in a higher equivalent permittivity of the gap medium. This leads to increased sensitivity and decreased required voltage. Although this system has gained popularity in recent years, a thorough understanding and accurate predictions of its behavior require a detailed mathematical model. Regrettably, the existing literature does not offer adequate information. The present model incorporates three coupled set of nonlinear differential equations that govern the longitudinal and transverse vibrations of the PDMS (Polydimethylsiloxane) pillars, as well as the transverse vibrations of the moving electrode. It demonstrates how the device's behavior is affected by varying tilt angles and numbers of micro-pillars. The viscoelastic properties of the PDMS pillars are also taken into account, following the Kelvin-Voigt model with non-linear strains. Numerical methods are used to solve the governing equations, enabling investigation of static deformation and vibrational responses under different DC (Direct Current) and DC+AC (Alternating Current) actuations. The nonlinear equations proposed in this study provide a valuable tool for accurately predicting the behavior of capacitive MEMS devices that use microstructured gaps with tilted micro-pillar arrays.

Heterostructured NiMo-sulfide micro-pillar arrays for advanced alkaline electrocatalytic clean hydrogen production via overall water splitting

Transition metals doped molybdenum sulfide/oxide present themselves as capable for hydrogen evolution reaction (HER), because of their exceptional chemical and physical properties. In this study, we introduce a strategy for synthesizing molybdenum-based binary sulfide/oxide heterostructures using a hydrothermal method. An electrochemical investigation revealed the pivotal role of NiMo-sulfide in achieving remarkable bifunctional electrocatalytic activity, resulting in a current density of −50 mA cm−2 at an overpotential of 174 mV for HER. The excellent reaction kinetics were evident from the low Tafel slope of 116.8 mVdec−1. The electrolyzer showcased outstanding performance, with the best-performing NiMo-sulfide and benchmark RuO2 at the anode. It achieved a low cell potential of 1.60 V to reach 10 mA cm−2, exhibited remarkable durability for 100 h, and demonstrated promise for water splitting with a Faradaic efficiency of 94 and 89 % for O2 and H2 evolution respectively. Furthermore, the electrolyzer displayed potential for large-scale hydrogen production by attaining an industrially appropriate current density of 800 mA cm−2 at a cell potential of 2.24 V. This study also highlights the latest advancements in electrodialysis to enhance the catalytic activity of electrode materials.

Morphologically reconfigurable magnetic micropillar arrays using acoustic streaming for particle capture and droplet manipulation

The accurate and efficient manipulation of particles and droplets is crucial for the fields of disease diagnosis, target drug delivery, and sample purification, specific microstructure-based particle and droplet manipulation have been widely utilized in bioassays. However, current techniques are mainly based on the fixed microstructures, which is extremely difficult to achieve dynamic modulation by adjusting microstructure morphology and excitation conditions. Herein, we present a novel particle capture and droplet manipulation methodology by using morphologically reconfigurable magnetic micropillar arrays incorporate with acoustic streaming effects, which enables reconfigurable particle capturing, cargo transportation, and droplet manipulation. The mechanism is to assemble NdFeB magnetic powders by magnetic gradient fields to form morphologically variable magnetic micropillar arrays with porous surfaces, and the localized acoustic streaming effects generated by surface acoustic waves (SAWs) enable micropillar arrays to capture nearby particles onto the surfaces or to drive perturbations in droplets in the vicinity. To demonstrate the capabilities of this technology, we have achieved the high-volume acoustofluidic particle capture and loading (0.214 MCF), targeted complex maze navigation, efficient droplets manipulation (≤ 3.96 mm/s), and acoustofluidic mixing acceleration (≤ 2.5 s). Therefore, this technique enables reconfigurable and versatile manipulation of particles and droplets in biomedical applications.

Effect of initial droplet position on coalescence-induced jumping on superhydrophobic surfaces with micropillar arrays

Coalescence-induced droplet jumping holds great potential for applications such as water harvesting, self-cleaning, and the thermal management of electronic devices. This study investigates the impact of the droplet's initial position on coalescence-induced jumping on superhydrophobic surfaces with micropillar arrays. Numerical simulations are conducted to examine the differences in droplet jumping at various initial positions with uniform and nonuniform micropillar distributions, and the effects of the droplet's initial position on its velocity and pressure distribution are analyzed. The findings indicate that altering the initial position produces an asymmetric distribution of the high-pressure region at the droplet's base and the pressure at the solid–liquid contact surface during the contraction of the liquid bridge. This asymmetry allows the droplet to jump away from the surface with both vertical and horizontal components of velocity, and to be transported in the horizontal direction. Furthermore, numerical simulations with various initial droplet positions and radii demonstrate that the direction of the horizontal jumping velocity is influenced by both the offset distance and the direction of the initial droplet position, and that the impact of the initial position decreases as the relative size of the droplet with respect to the micropillars increases. The droplet jumping velocity, direction, and horizontal transport distance can be controlled by adjusting the initial droplet position and size. This work reveals the mechanism of coalescence-induced droplet jumping on superhydrophobic surfaces with micropillar arrays and provides an important reference for practical applications.

Corrosive effect on saturated pool boiling heat transfer characteristics of metallic surfaces with hierarchical micro/nano structures

Surface modification is of critical interest to enhance boiling heat transfer in terms of heat transfer coefficient or critical heat flux (CHF), which is significantly affected by distinct surface morphology and wettability and it can improve the efficiency and safety of equipment. Furthermore, actual service environment may cause severe corrosion to the processed structured surfaces while its consequence on boiling heat transfer is still obscure. In this article, comprehensive researches are conducted to unravel corrosive effect on metallic samples made of stainless steel (SS) and Inconel materials with microstructures. Different constructions (i.e., microgroove, microcavity and micropillar array) and characteristic dimensions (∼20, 50 μm) of microstructure, various duration time (up to 300 days) and pH values (∼7.0–8.5) of corrosive environment are compared thoroughly. Conclusions can be drawn that not all microstructures can enhance pool boiling heat transfer characteristics, especially in terms of CHF values. More importantly, CHF value of SS microgroove sample firstly increases from 60.94 to 94.09 W·cm−2 in 50 days, then decreases to 47.77 W·cm−2 in 300 days, which can be attributed to competition result between formation of hierarchical micro/nano structure with enhancing wicking capability and chemistry condition with increasing contact angle. In addition, distinct bubble dynamics during pool boiling is also analyzed. The insights obtained from this article can be used to guide surface modification method and to reveal evolvement rule of engineered metallic surface in highly corrosive and harsh boiling heating transfer environment.

Design and Testing of a New Microinjector With Capacitive Force Sensor for Biological Microinjection

Microinjection with force sensing plays an important role in delivering foreign materials into biological entities. In this paper, a new force-sensing microinjector with compliant mechanism is presented. It provides a high sensitivity of force sensing by offering a small stiffness in the direction of microinjection. Meanwhile, it enables a sufficient load-bearing capability thanks to a large stiffness in the lateral direction. The small stiffness is realized by the combination of a positive-stiffness mechanism and a negative-stiffness mechanism, rather than a zero-stiffness mechanism. A custom-made capacitive force sensor based on tilted micropillar array is introduced to measure the microinjection force based on the microinjector’s output displacement. Moreover, a prototype has been fabricated for experimental testing. Experimental results show that the sensitivity of the proposed design has been improved by two-fold over previous work. The developed microinjector has been applied to successfully detect the microinjection force during the injection of zebrafish larvae, which renders a promising solution for regulating the microinjection force. <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">Note to Practitioners</i> —Force-assisted microinjection can provide force feedback, which is desirable to protect biological samples from excessive force and to judge successful penetration. Currently, most existing force sensor-based microinjectors can only puncture biological samples, rather than injecting materials, mainly due to the inability of bearing the weight of linker for the injection needle and actuator. In this work, a new microinjector with capacitive force sensor is presented for microinjection of zebrafish larvae. Based on the combination of a positive-stiffness mechanism and a negative-stiffness mechanism, a small-stiffness mechanism is introduced to design the microinjector. It simultaneously provides large axial sensitivity and large lateral loading ability. Moreover, a capacitive force sensor based on tilted micropillar array is devised to measure the microinjection force based on the overall displacement of the microinjector. For fixing zebrafhish larvae, a micro-array petri dish is fabricated by silicon wafer mould. Experimental results show that the microinjector is capable of delivering foreign materials and detecting the microinjection force, which is beneficial to the microinjection operation.

Micropatterned Hydrogel‐Elastomer Hybrids for Flexible Wet‐Style Superhydrophobic Antifogging Tapes

AbstractTransparent materials widely used in applications such as eyewear, solar cells, and optical devices, often suffer from environmental challenges including fogging, surface contamination, and mechanical deformation. However, a universal strategy that resolves all these issues in a single platform remains to be resolved. Herein, a monolithic micropillar structure based on polydimethylsiloxane (PDMS) elastomer is prepared followed by subsequent assembly of hydrogel micropatterns in between the micropillar array using inkjet printing to achieve flexible wet‐style superhydrophobic antifogging tapes that are applicable to various transparent materials and curvatures. The monolithic micropillar structure with low‐surface‐energy characteristics facilitates easy removal of surface contaminants by rinsing with water while granting mechanical durability. In addition, micropatterning of hydrogels via inkjet printing not only enables to maintain optical transparency in a fogging environment but also makes the fabrication procedure more scalable. Furthermore, the strong adhesion between the hydrogel and the elastomer is shown to provide enhanced stability under repeated stretching cycles and long‐term exposure to water while the presence of a loosely cross‐linked PDMS at the bottom of the tape made it applicable to a wide range of transparent substrates without using additional adhesives.

The Shape Effect of Acoustic Micropillar Array Chips in Flexible Label-Free Separation of Cancer Cells.

The precise isolation of circulating tumor cells (CTCs) from blood samples is a potent tool for cancer diagnosis and clinical prognosis. However, CTCs are present in extremely low quantities in the bloodstream, posing a significant challenge to their isolation. In this study, we propose a non-contact acoustic micropillar array (AMPA) chip based on acoustic streaming for the flexible, label-free capture of cancer cells. Three shapes of micropillar array chips (circular, rhombus, and square) were fabricated. The acoustic streaming characteristics generated by the vibration of microstructures of different shapes are studied in depth by combining simulation and experiment. The critical parameters (voltage and flow rate) of the device were systematically investigated using microparticle experiments to optimize capture performance. Subsequently, the capture efficiencies of the three micropillar structures were experimentally evaluated using mouse whole blood samples containing cancer cells. The experimental results revealed that the rhombus microstructure was selected as the optimal shape, demonstrating high capture efficiency (93%) and cell activity (96%). Moreover, the reversibility of the acoustic streaming was harnessed for the flexible release and capture of cancer cells, facilitating optical detection and analysis. This work holds promise for applications in monitoring cancer metastasis, bio-detection, and beyond.

On the contribution of the top and bottom walls in micro-pillar array columns and related high-aspect ratio chromatography systems

We report on a steady-state based, and hence highly accurate numerical modelling study of the effect of the top and bottom wall in the current generation of micro-pillar array columns. These have a mesoporous retention layer that not only covers the pillar walls but also the bottom wall. Our results show that the performance of these columns can in general not be improved by also covering the top wall with the same layer, despite the increased column symmetry this approach would offer. The reason for this is that the local species retardation caused by a retentive layer is much stronger than the pure flow arresting effect of an uncovered wall. At least, this has a crucial impact in high aspect-ratio systems such as micro-pillar array columns because these require a small inter-pillar distance to promote mass transfer together with a large channel depth to enable a sufficiently high flow rate. On the other hand, a notable improvement could be made if micro-pillar array would be produced without having a retentive layer at the bottom. At Péclet number Pe = 50 and aspect ratio AR = 5 for flow-channels, this gain amounts up to about 4.5 h-units at a zone retention factor k’’ = 2 and 1.75 h-units at k’’ = 16 (gain scales almost linearly with Pe).To verify these results, we also considered another high aspect-ratio system with a simplified geometry: the open-tubular channel with a flat-rectangular cross-section. This led to very similar observations, thus confirming the findings for the micro-pillar array.The results produced in the present study also allow us to conclude that the classic modelling paradigm adopted in chromatography, which is based on the independency and hence additivity of the hCm- and hCs-contributions, can lead to large modelling errors in chromatographic systems with a high aspect-ratio, even when their geometry is so simple as that of a straight open-tubular channel with constant cross-section. Indeed, when both zones are treated independently, the analysis misses how the vertical diffusion through the retentive layer helps suppressing the vertical gradients in the mobile zone. The diffusion through this layer occurs in a ratio of k’’Ds/Dm (Dm being the diffusion coefficient in mobile phase zone and Ds being the diffusion coefficient in stationary phase zone), such that at high retention factors this diffusion contribution even becomes the dominant one.

Experimental study on ultra-thin silicon-based VC for chip-level heat dissipation

The trend towards miniaturization and integration of integrated circuits has led to the emergence of local hotspots with high heat flux and high temperature frequently. Integrating vapor chamber (VC) directly on the surface of semiconductor electronic devices, can effectively address the problem of overheating on the chip surface, and is therefore considered as a promising thermal management solution. However, the challenge of reducing the size of the VC while improving its heat transfer performance cannot be ignored. To address this, a silicon-based VC with thickness of 0.6 mm is designed and fabricated in this study. Structural optimization is carried out, including the design of three types of wicks using square micropillar arrays and two types of support columns including solid and porous and an experimental system is built to study the influence of these structures on the heat transfer performance of VC. The results indicate that the VC can still function normally under the highest heat flux of 123.6 W/cm2, resulting in lowest thermal resistance of 1.54 °C/W. For wicks, the thermal resistance of VC with characteristic size of 10 μm is reduced compared with that of 20 μm. The introduction of gradient wick, that is, using small-size (10 μm) micropillar arrays in heating area and big-size (20 μm) micropillar arrays in non-heating area, can effectively reduce the thermal resistance of VC. Moreover, the solid support columns are found being advantageous in reducing the thermal resistance of VC, while porous support columns improve the surface temperature uniformity of VC. This work provides a feasible path to optimize silicon-based VC.

Effect of surface peak-valley features on the fluid flow performance in rough contact interface

In this work, two kinds of microtextured surfaces with different surface peak-valley features, namely positively skewed surface with micropillar array and negatively skewed surface with micropit array, are prepared to explore the effect of peak-valley features on the fluid flow performance in rough contact interface. The distribution and connectivity of microchannels is analyzed, and the physical mechanism of peak-valley features inducing different fluid flow processes is also derived through constructing a kinetic model of fluid spreading. It is found that when the surface skewness Ssk &amp;gt; 0, the positively skewed surface forms the void regions with better connectivity in the interface compared with the negatively skewed surface (Ssk &amp;lt; 0), despite both the surfaces having nearly the same roughness (Sa ∼ 3.6 mm). The formed microchannels are defined as crossed open microchannel and semi-closed microchannel, respectively, and the feature length of the microchannel decreases with the increase in load. The quantitative results of fluid flow demonstrate that the liquid has a better spreading and flow ability in the contact interface of the positively skewed surface. Even under the same microchannel feature length (nearly 48 mm), the fluid spread area ratio of the positively skewed surface has an order of magnitude higher than that of the negatively skewed surface. The mechanism of different flow characteristics induced by surface peak-valley features is believed as the variation of the microchannel shape, leading to the change in the capillary pressure at the meniscus. We believe the present work would lay a theoretical foundation for regulating the microscopic flow behavior in the contact interface.

Theoretical optimization of micropillar arrays for structurally stable bioinspired dry adhesives

Inspired by the excellent adhesion performances of setae structure from organisms, micro/nano-pillar array has become one of the paradigms for adhesive surfaces. The micropillar arrays are composed of the resin pillars for adhesion and the substrate with different elastic modulus for supporting. The stress singularity at the bi-material corner between the pillars and the substrate can induce the failure of the micropillar-substrate corner and further hinder the fabrication and application of micropillar arrays, yet the design for the stability of the micropillar array lacks systematical and quantitative guides. In this work, we develop a semi-analytical method to provide the full expressions for the stress distribution within the bi-material corner combining analytical derivations and numerical calculations. The predictions for the stress within the singularity field can be obtained based on the full expressions of the stress. The good agreement between the predictions and the FEM results demonstrates the high reliability of our method. By adopting the strain energy density factor approach, the stability of the pillar-substrate corner is assessed by predicting the failure at the corner. For the elastic mismatch between the pillar and substrate given in this paper, the stability can be improved by increasing the ratio of the shear modulus of the substrate to that of the micropillar. Our study provides accurate predictions for the stress distribution at the bi-material corner and can guide the optimization of material combinations of the pillars and the substrate for more stable bioinspired dry adhesives.

Micro-feature fabrication on SS304 stainless steel using WEDM process

ABSTRACT Fabricating micro-pillars is a tough procedure as these features are highly debile. Wire Electro-Discharge Machining (WEDM) is a popular micromachining process to fabricate complex features on electrical conducting materials. SS304 stainless steel is commonly used in manufacturing of heating and cooling devices. A simple method of micro-pillars array fabrication on SS304 Stainless Steel material using WEDM was used through perpendicular crossed wire movement, keeping specified amount of step-over distance to form pillars. An analytical model for material removal rate prediction was developed using input parameters like spark duration, off time, voltage and current. Also, the influence of the process parameters was studied on depth and kerf width produced. Voltage and pulse-on time were found to be the major influencing parameters. Micro-featured surfaces fabricated for minimum kerf width and maximum feature depth were analysed using SEM and EDS along with the wettability study. The fabricated surfaces remained hydrophobic even after 100s.