Thickness Control Research Articles

Scaling up multispectral color filters with binary lithography and reflow (BLR)

Abstract Efforts to increase the number of filters are driven by the demand for miniaturized spectrometers and multispectral imaging. However, processes that rely on sequential fabrication of each filter are cost ineffective. Herein, we introduce an approach to produce at least 16 distinct filters based on a single low-resolution lithographic step with minimum feature size of 0.6 μm. Distinct from grayscale lithography, we employ standard binary lithography but achieve height variations in polymeric resist through a post-development reflow process. The resulting transparent polymeric films were incorporated in Fabry–Perot cavity structures with cavity thickness ranging from 90 to 230 nm to produce transmittance across the visible spectrum. This binary lithography and reflow (BLR) process demonstrates control of the dielectric layer thickness down to ∼15 nm. This new process provides a cost-effective alternative to traditional techniques in fabricating microscopic transmission filters, and other applications where precise thickness variation across the substrate is required.

Influence of midday removal and re-application of a scleral lens on fluid reservoir thickness, pre-lens tear film quality and visual acuity

PurposeTo investigate whether the midday removal and re-application of scleral lenses (SL) influences fluid reservoir (FR) thickness, pre-lens tear film quality and visual acuity. MethodsTwo clinical experiments were conducted. A total of 49 keratoconic eyes were evaluated for Part1(tear film and visual acuity analysis) and 12 keratoconic eyes for Part2 (FR thickness analysis). All subjects were wearing 16.4 mm SL for more than 12-months. Tear Film Surface Quality (TFSQ) was evaluated with Medmont E300 at more than 120 min of SL wear, 10 min after SL removal (pre-corneal TFSQ) and 5 min after re-apply the same SL. High and Low Contrast Visual Acuity (HCVA and LCVA) were also assessed with the SL on eye (before and after re-application). For Part2, Anterior OCT (MOptim MOcean4000, China) measurements were taken with and without the SL (at the same time points of Part1) and three outcomes were evaluated: FR thickness, SL thickness (control measurement) and corneal thickness. ResultsRemoving and re-applying a SL had a statistically significant positive impact on TFSQ, with an improvement from 0.26 ± 011 to 0.16 ± 0.08 (p = 0.001). This was accompanied by a statistically significant improvement in LogMAR HCVA (from 0.10 ± 0.09 to 0.08 ± 0.08, p < 0.001) and LCVA (from 0.39 ± 0.13 to 0.36 ± 0.13, p < 0.001). Regarding Part2 of the study, a statistically significant increase in FR thickness was observed after SL re-application (from 223.64 ± 48.08 µm to 267.81 ± 80.03 µm, p = 0.007). No changes in corneal thickness were observed. ConclusionsMidday removal and re-application of a scleral lens positively impacted pre-lens tear film surface quality, although the observed improvement in visual acuity does not constitute a clinically significant change. Clinicians should consider that removing and reapplying a scleral lens may result in an overestimation of the fluid reservoir thickness, which could affect clinical assessments and treatment decisions.

Film thickness characterization in dual-axis spin coating of a sphere

The versatility of spin coating technology makes it a preferred method for producing the thin film layers used to manufacture products from solar panels and smartphones to sunglasses and CDs. However, the process requires a flat, rigid substrate to produce uniform films, which limits its use to planar devices. A novel multi-axis manipulator has been developed to extend the application of spin coating, enabling controlled thin film deposition onto curved surfaces. Various rotational schemes were studied to link the flow of a liquid film over a curved surface to forces induced by complex rotational dynamics. When the angular velocity exceeds a threshold, centrifugal force dominates the flow, pushing the fluid away from the instantaneous axis of rotation. This produces axisymmetric coating profiles when using consistent single or dual-axis rotation. Areas of near uniformity present around the spin axis poles for single-axis rotation and around the substrate’s equator for dual-axis schemes. Sensitivities between the spherical substrate dynamics and the evolving fluid flow were investigated, exploring the parameters that promoted the production of uniform curved film layers for microfabrication processes. This enabled the evolution of the spin coating technique to effectively form curved polymer coatings with improved thickness control. The presented research outlines the capabilities of a multi-axis spin coating machine when used to coat spherical substrates. Therefore, enabling the use of fluid mechanics models to identify the optimal motion kinematics required to create uniform curved films.

Bidimensional Spectroelectrochemistry with Tunable Thin-Layer Thickness.

Bidimensional spectroelectrochemistry (Bidim-SEC) is an instrumental technique that provides operando UV/vis absorption information on electrochemical processes from two different points of view, using concomitantly a parallel and a normal optical configuration. The parallel configuration provides information about chemical species present in the diffusion layer, meanwhile the normal arrangement supplies information about changes occurring both in the diffusion layer and, mainly, on the electrode surface. The choice of a suitable cell to perform Bidim-SEC experiments is critical, especially while working under a thin-layer regime. So far, most of the proposed Bidim-SEC cells rely on the use of spacers to define the thin-layer thickness, which leads to working with constant thickness values. Herein, we propose a novel Bidim-SEC cell that enables easy-to-use micrometric control of the thin-layer thickness using a piezoelectric positioner. This device can be used for the study of complex interfacial systems and also to easily measure the key parameters of an electrochemical process. As a proof of concept, the study of the roughening of a gold electrode in KCl medium is performed, identifying key steps in the passivation and nanoparticle generation on the gold surface.

UiO-66-NH2/hydrothermal carbon nanocomposite assembled mesh membrane with photocatalytic self-cleaning and antibacterial properties for on-demand oily wastewater separation

The poor wettability, limited permeation flux and unsatisfactory anti-fouling property of oil/water separation membranes significantly hinder their practical application. This study developed a novel UiO-66-NH2/hydrothermal carbon@stainless steel mesh (UiO/HC@SSM) membrane, fabricated through a straightforward dip-coating strategy that offers membrane thickness control. The resulting membrane exhibited superhydrophilic/underwater superoleophobic property and high porosity, enabling gravity-driven separation of emulsified and stratified oil/water mixtures on-demand with high separation efficiency and superior flux. Specifically, UiO/HC@SSM-5 (dip-coating five times) showed ultrahigh permeate fluxes of 51428–56425 L m−2 h−1 for stratified oil/water mixtures separation, and UiO/HC@SSM-10 exhibited interface demulsification and gravity separation ability for emulsified oil/water mixtures with high fluxes of 4050–4504 L m−2 h−1. Notably, UiO/HC nanocomposite endowed the membrane with exceptional photocatalytic self-cleaning and antibacterial activities, effectively addressing both oil and microbial fouling. High-viscosity crude oil fouling can be light-induced decontaminated from the composite membrane surface with superior flux recovery ratio (FRR) up to 97 %. The as-prepared UiO/HC@SSM also exhibited near-complete bacterial inactivation activity after 10 min of visible light irradiation. Encouragingly, UiO/HC@SSM demonstrated superior separation and photocatalytic capabilities compared to UiO@SSM, attributed to the dual promoting role of cost-effective hydrothermal carbon in hydrophilicity and photoelectric properties. Moreover, UiO/HC modified SSM membrane displayed robust chemical and mechanical stability, coupled with superior harsh environments and oil pressure resistances. This membrane, boasting desirable wettability, high permeability, exceptional photocatalytic activity, and excellent stability, offers a reliable solution for treating complex oily wastewater. Additionally, the demulsification and photocatalysis mechanisms of UiO/HC@SSM membrane were examined in depth. This study holds significant potential in advancing the development of novel SSM membranes functionalized with MOF/carbon material, thereby enhancing their practical applications in purifying oily wastewater.

Two-Step Conversion of Metal and Metal Oxide Precursor Films to 2D Transition Metal Dichalcogenides and Heterostructures.

The widely studied class of two-dimensional (2D) materialsknown as transition metal dichalcogenides (TMDs) are now well-poised to be employed in real-world applications ranging from electronic logic and memory devices to gas and biological sensors. Several scalable thin film synthesis techniques have demonstrated nanoscale control of TMD material thickness, morphology, structure, and chemistry and correlated these properties with high-performing, application-specific device metrics. In this review, the particularly versatile two-step conversion (2SC) method of TMD film synthesis is highlighted. The 2SC technique relies on deposition of a solid metal or metal oxide precursor material, followed by a reaction with a chalcogen vapor at an elevated temperature, converting the precursor film to a crystalline TMD. Herein, the variables at each step of the 2SC process including the impact of the precursor film material and deposition technique, the influence of gas composition and temperature during conversion, as well as other factors controlling high-quality 2D TMD synthesis are considered. The specific advantages of the 2SC approach including deposition on diverse substrates, low-temperature processing, orientation control, and heterostructure synthesis, among others, are featured. Finally, emergent opportunities that take advantage of the 2SC approach are discussed to include next-generation electronics, sensing, and optoelectronic devices, as well as catalysis for energy-related applications.

An industrial IoT-based deformation resistance prediction and thickness control method of cold-rolled strip in steel production systems

Different from traditional analytical and numerical simulation methods, data-driven methods can more effectively describe the effects of nonlinear and coupling factors. Although the fluctuations of deformation resistance and thickness for hot-rolled strips significantly influence the thickness accuracy in strip cold rolling, the traditional deformation resistance prediction model and thickness control mode don't involve that. Thus, based on the Industrial Internet of Things (IIOT) platform and data-driven technology, this work proposed a new method for deformation resistance prediction and a new mode of feed-forward control for strip thickness. IIOT platform can collect production data from the various levels to provide a complete data set. The deformation resistance prediction model is established by adopting the differential evolutionary algorithm to optimize the bi-directional long and short-term memory network. In addition, the feed-forward control (DFFC) strategy for strip thickness is proposed based on deformation resistance prediction. An application results of a 1420 mm production line of CR indicated that the established prediction model could provide a high accuracy prediction for deformation resistance, and compared to traditional thickness gauges-based automatic gauge control methods, the DDFC can capture the effect of the fluctuations of deformation resistance and thickness for the hot-rolled strip to improve thickness accuracy effectively.

General strategy for developing thick-film micro-thermoelectric coolers from material fabrication to device integration

Micro-thermoelectric coolers are emerging as a promising solution for high-density cooling applications in confined spaces. Unlike thin-film micro-thermoelectric coolers with high cooling flux at the expense of cooling temperature difference due to very short thermoelectric legs, thick-film micro-thermoelectric coolers can achieve better comprehensive cooling performance. However, they still face significant challenges in both material preparation and device integration. Herein, we propose a design strategy which combines Bi2Te3-based thick film prepared by powder direct molding with micro-thermoelectric cooler integrated via phase-change batch transfer. Accurate thickness control and relatively high thermoelectric performance can be achieved for the thick film, and the high-density-integrated thick-film micro-thermoelectric cooler exhibits excellent performance with maximum cooling temperature difference of 40.6 K and maximum cooling flux of 56.5 W·cm−2 at room temperature. The micro-thermoelectric cooler also shows high temperature control accuracy (0.01 K) and reliability (over 30000 cooling cycles). Moreover, the device demonstrates remarkable capacity in power generation with normalized power density up to 214.0 μW · cm−2 · K−2. This study provides a general and scalable route for developing high-performance thick-film micro-thermoelectric cooler, benefiting widespread applications in thermal management of microsystems.

All-electrochemical synthesis of SnBi/SnAgCu structures for low-temperature formation of high-reliability solder microjoints

There is a growing interest in low temperature soldering, yet the use of low-melting point alloys for interconnection is often hindered by reliability concerns. Eutectic tin-bismuth (SnBi) alloy is being considered for soldering to Sn3Ag0.5Cu (SAC305) bumps at lower temperatures (150 °C), but the resulting hybrid structures are not very reliable. We have recently shown that superior reliability can be achieved by a post-soldering anneal to distribute up to 6 % Bi throughout the joint. However, the new approach is impractical for solder joints taller than 70 µm and the manufacturing feasibility in such cases warrants both SnBi and SAC305 to be electroplated. The present study utilizes electrochemistry to broaden the applicability of the aforementioned approach by the development of optimized routines for the separate electroplating of both structural alloys. The synthesis of the SAC305 alloy employs elemental co-deposition under strict thickness control, and the SnBi eutectic mixture may be produced likewise and deposited atop to enable low-temperature soldering. If the SnBi is deposited on separate pads, better composition control may be achieved alternatively by the successive plating of both metals, followed by reflow to facilitate their mixing. The established plating routines are further fine-tuned for the processing of an array of pillars.

Solution-processable low-voltage carbon nanotube field-effect transistors with high-k relaxor ferroelectric polymer gate insulator

Achieving energy-efficient and high-performance field-effect transistors (FETs) is one of the most important goals for future electronic devices. This paper reports semiconducting single-walled carbon nanotube FETs (s-SWNT-FETs) with an optimized high-k relaxor ferroelectric insulator P(VDF-TrFE-CFE) thickness for low-voltage operation. The s-SWNT-FETs with an optimized thickness (∼800 nm) of the high-k insulator exhibited the highest average mobility of 14.4 cm2 V−1s−1 at the drain voltage (I D) of 1 V, with a high current on/off ratio (I on/off >105). The optimized device performance resulted from the suppressed gate leakage current (I G) and a sufficiently large capacitance (>50 nF cm−2) of the insulating layer. Despite the extremely high capacitance (>100 nF cm−2) of the insulating layer, an insufficient thickness (<450 nm) induces a high I G, leading to reduced I D and mobility of s-SWNT-FETs. Conversely, an overly thick insulator (>1200 nm) cannot introduce sufficient capacitance, resulting in limited device performance. The large capacitance and sufficient breakdown voltage of the insulating layer with an appropriate thickness significantly improved p-type performance. However, a reduced n-type performance was observed owing to the increased electron trap density caused by fluorine proportional to the insulator thickness. Hence, precise control of the insulator thickness is crucial for achieving low-voltage operation with enhanced s-SWNT-FET performance.

Research on Multi-System Coupling Vibration of a Hot Tandem Mill

Vibration in hot tandem rolling mills has been a problem in the iron and steel industry mainly due to its unpredictability. In this work, vibration data of the second finishing mill (F2) stand of a hot tandem rolling mill are collected and analyzed, and a mathematical model based on the coupling of a non-uniform deformation process, mill structure and hydraulic control system is constructed. The influence of different inlet thickness fluctuation forms, structural parameters and control parameters on the vibration behavior is analyzed. It is concluded that the low-frequency thickness fluctuation with additional skewness can cause the resonance of each subsystem of the rolling mill. The deviation angle of the roll system influences the vibration harmonic output of the rolling mill under a single low-frequency thickness fluctuation excitation. The compensation parameter in the thickness control system affects the natural frequency of the vertical system.

Transparent supercapacitors with networked MXene on NiCo-layered double hydroxide

This study investigates the growth mechanisms of NiCo-layered double hydroxide (LDH) electrodeposition on indium tin oxide (ITO) substrates, aiming to optimize thickness control for transparent supercapacitor applications. Despite the promising energy storage capabilities of NiCo-LDH, long-term cycle stability and transparency degradation due to irreversible redox reactions limit its applicability. To address these challenges, we introduced networked MXene nanosheets into the NiCo-LDH matrix, significantly enhancing electrochemical properties and cycle resilience while maintaining excellent transparency. Under optimized conditions, NiCo-LDH and MXene composites achieved an impressive areal capacitance of 136.9F cm−2 and retained 74.2 % capacitance even after 7000 charge–discharge cycles. Notably, the transparency of the composite remained strong at 80.1 %, outperforming NiCo-LDH without the networked MXene, which retained only 51.4 % transparency after the same cycles, thus indicating that the well-networked MXene nanosheets played a crucial role in improving electrical conductivity and charge-transfer efficiency across the electrode surface. The transparent symmetric supercapacitor developed, utilizing MXene-coated NiCo-LDH, demonstrated outstanding performance with an energy density of 2.23 µWh cm−2 at a power density of 120.00 µW cm−2. Moreover, it showcased an admirable capacitance retention of 85.9 % following 9000 charge–discharge cycles, underlining the robustness of the composites and efficiency for transparent supercapacitor applications. In conclusion, this research highlights the potential of NiCo-LDH/MXene composites for transparent supercapacitors. By carefully controlling thickness and optimizing MXene concentration, we effectively addressed durability and transparency challenges during extended charge–discharge cycles.

Cooperatively tuning magnetic anisotropy and colossal magnetoresistance via atomic-scale buffer layers in highly strained La0.7Sr0.3MnO3 films

Achieving simultaneous control over multiple functional properties, such as magnetic anisotropy, magnetoresistance, and metal-insulator transition, with atomic precision remains a major challenge for realizing advanced spintronic functionalities. Here, we demonstrate a unique approach to cooperatively tune these multiple functional properties in highly strained La0.7Sr0.3MnO3 (LSMO) thin films. By inserting varying perovskite buffer layers, compressively strained LSMO films transition from a ferromagnetic insulator with out-of-plane magnetic anisotropy to a metallic state with in-plane anisotropy. Remarkably, atomic-scale control of the buffer layer thickness enables precise tuning of this magnetic and electronic phase transformation. We achieve a colossal magnetoresistance tuning of 10,000% and an exceptionally sharp transition from out-of-plane to in-plane magnetic anisotropy within just a few atomic layers. These results demonstrate an unprecedented level of control over multiple functional properties, paving the way for the rational design of multifunctional oxide spintronic devices.

Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality.

This research investigates the control of thickness and weight in plastic extrusion vacuum-thermoforming products to identify optimal key parameters for cost reduction and energy savings. The initial step involves identifying crucial influencing factors. In this step, the Delphi technique was employed through a questionnaire administered to a panel of expert scholars to ensure minimal error and maximal reliability in determining key influencing factors. Consensus was sought to establish appropriateness and consistency. Subsequently, the Taguchi method was applied for quality design and planning of the extrusion vacuum-forming process. The experimental design parameters were selected using an L18 (21 × 37) orthogonal array, and the desired quality characteristics were determined. Comparative analysis of quantitative production data from two consecutive experiments was conducted, and based on F-values and contribution analysis, the combination of control factors maximizing the Signal-to-Noise (S/N) ratio was identified. The objective is to seek optimal parameters for improving the quality of the plastic polypropylene (PP cup lid) manufacturing process, reducing process variability, and identifying the most robust production conditions. Through multiple actual production prediction experiments, it was determined that five control factors, "polypropylene new material ratio," "T-die lips adjustment thickness", "mirror wheel temperature stability", "molding vacuum pressure time", and "forming mold area design", contribute to the maximization of the S/N ratio, i.e., minimizing variability. Statistical validation confirms a significant improvement in product quality and weight control. Noteworthily, the quality control model and experimental design parameters established in this study are also applicable to other plastic products and bio-based materials, such as PET, HIPS, and biodegradable PLA lids with added calcium carbonate. The results of the experimental production demonstrate its ability to consistently control product weight within the range of 3.4 ± 0.1 g, approaching the specified tolerance limits. This capability results in approximately 2.6% cost savings in product weight, contributing significantly to achieving a company's KPI goals for environmental conservation, energy efficiency, and operational cost reduction. Therefore, the findings of this study represent a substantial and tangible contribution.

Photocatalytic Nitrate Reduction over TiO2 Layers on Glass Rings Generated by Dip‐Coating

AbstractThe support of powdered catalysts on mold bodies facilitates their handling and reusability. In case of photocatalytic applications, such as enhanced water purification processes, transparent supports with thin layers of the active material are desirable to obtain an optimal light efficiency. For the generation of such layers a precise control of layer thickness is crucial. Here, a multi‐step dip‐coating approach for the generation of TiO2 layers with varying thickness on glass rings is reported. Additionally, the coated glass rings were tested in the photocatalytic reduction of nitrate in aqueous solution under simulated sunlight.

A CASE OF TREATMENT OF CONGENITAL ICHTHYOSIS IN A NEWBORN CHILD

Congenital ichthyoses (CI) are a group of rare inherited disorders that cause keratinization defects. This group includes hereditary ichthyosis and hereditary syndromes with ichthyosiform lesions. Offi cial statistics are not yet available in Ukraine. The most common clinical manifestation is nonbullous hyperkeratosis characterized by thick hyperkeratotic scales, skin thickening, severe skin dryness and erythema. In more severe forms – ectropion, eclabion. Skin permeability is increased in CI patients, resulting in increased fl uid and calorie loss, diffi culty in thermoregulation, and reduced elasticity, which limits mobility. Symptoms can vary in severity, but severe manifestations at birth are not always indicative of a more severe course later in life. Challenges in defi nitive diagnosis are due to the need for karyotyping, which is quite expensive. Currently available treatment modalities include continuous moisturization, reduction of transepidermal water loss, control of hyperkeratotic layer thickness (reducing it to a minimum) with local keratolytics, emollients, and systemic retinoids in severe cases. The article presents a clinical case of successful local treatment of CI with a pronounced eff ect without the use of systemic retinoids. The publication of the materials has been approved by the Bioethics Commission of the CI «Regional Medical Center for Family Health» DRC». All anamnestic data, examination results and photographs are provided with prior written consent of the parents. Conclusion. Congenital ichthyoses require careful monitoring. The initial clinical manifestations can not be a marker for the severity of the disease course.

Modulation of Spin and Lattice Dynamics by Thickness Control of Tb in Si/CoFe/Tb/Al Thin Films

Modulation of Spin and Lattice Dynamics by Thickness Control of Tb in Si/CoFe/Tb/Al Thin Films

A review on the design and fabrication of polydimethylsiloxane thin-film composite membranes (TFCMs) for alcohol permselective pervaporation

Pervaporation-based membrane technology have gained increasing interest due to their energy efficiency and environmental sustainability. Polydimethylsiloxane (PDMS) thin-film composite membranes (TFCMs) have emerged as promising candidates for alcohol permselective applications. Compared to the development of pervaporation membrane for water purification, the optimization progress with the ethanol recovery membrane has been fairly slow and fails to meet requirements of bio-alcohol production. Despite the continuous efforts on membrane materials, the role of structural, physicochemical properties for the forming progress of selective layer on substrate is not a well-attended topic. This paper summarized the design and construction considerations of PDMS composite membranes for pervaporation from the viewpoint of the transport resistance model, including the effect of selective layer, support layer, and intermediate layer, to deeply understand and precisely regulate the preparation process. We high light the key role of crosslinking and spreading of PDMS on porous support layer in membrane fabrication. The structure-activity relationship between the separation performance of transport structure with the membrane solution properties, substrate pore structure, and the fabrication methods was discussed in detail. It was indicated that the challenges for the TFCMs applied on a pilot or industrial scale include the thickness control, coating and curing time optimization, and solvent issue. Finally, it was expected for further research to optimize the membrane fabrication process, develop novel advanced membrane materials and to explore complex and potential applications the new requirements in industry.

Area-selective atomic layer deposition (AS-ALD) of low temperature (300 °C) cobalt thin film using octadecyltrichlorosilane (ODTS) self-assembled monolayers (SAMs)

As the semiconductor industry advances, manufacturing technologies encounter challenges in achieving precise alignment and thickness control with smaller and more intricate 3D structures. Addressing this, Area-selective atomic layer deposition (AS-ALD) emerges as a promising “bottom-up” approach, offering an alternative to current nano-patterning techniques. To achieve AS-ALD, self-assembled monolayers (SAMs) are employed as inhibitor agents. In this study, we employed plasma-enhanced atomic layer deposition (PEALD) to promote self-limiting surface reactions and enable low-temperature processing, thereby facilitating the implementation of high purity cobalt (Co) film through AS-ALD using octadecyltrichlorosilane (ODTS) SAM as an inhibitor. The selective deposition is achieved by employing SAMs as an inhibitor, belonging to the deactivation process, a common method for realizing a bottom-up approach. SAMs can form a thin organic film on a solid surface, allowing for surface modifications to become hydrophobic or hydrophilic. Through the selective deposition of Co in the PEALD low-temperature process (300 °C), we successfully addressed the degradation issue of ODTS SAM and verified the successful achievement of a high-purity selectively deposited 13.4 nm Co film. Our findings highlight the potential of selective Co deposition for realizing complex 3D structures and narrow interconnection layers.

A 3D voxel-based mesostructure generator for finite element modelling of tow-based discontinuous composites

Tow-based discontinuous composites manufactured with ultra-thin tapes display high stiffness, strength, and in-plane isotropy, thus competing with composite laminates. Their complex 3D microstructure affects the mechanical response, in turn demanding 3D generators that capture the tape waviness, resin pockets, and thickness and fibre content variations. The present work proposes an automated numerical framework combining a 3D voxel-based mesostructure generator with finite element models. A modified 3D random sequential absorption technique is developed with bin-guided allocation, draping, and thickness control. A statistical study is used to size the statistical volume elements and predict the elastic properties of thick, thin, and ultra-thin tow-based discontinuous composites. The results are compared with the experimental values from the literature. Despite uncertainties in physical tape properties, the resulting stiffnesses are predicted with good accuracy.