Generation of precision microstructures based on reconfigurable photoresponsive hydrogels for high-resolution polymer replication and microoptics

Pang Zhu, Qingchuan Song, Sagar Bhagwat, Fadoua Mayoussi, Andreas Goralczyk, Niloofar Nekoonam, Mario Sanjaya, Peilong Hou, Silvio Tisato, Frederik Kotz-Helmer, Dorothea Helmer () and Bastian E. Rapp
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Pang Zhu: Albert Ludwig University of Freiburg
Qingchuan Song: Albert Ludwig University of Freiburg
Sagar Bhagwat: Albert Ludwig University of Freiburg
Fadoua Mayoussi: Albert Ludwig University of Freiburg
Andreas Goralczyk: Albert Ludwig University of Freiburg
Niloofar Nekoonam: Albert Ludwig University of Freiburg
Mario Sanjaya: Glassomer GmbH
Peilong Hou: Albert Ludwig University of Freiburg
Silvio Tisato: Albert Ludwig University of Freiburg
Frederik Kotz-Helmer: Albert Ludwig University of Freiburg
Dorothea Helmer: Albert Ludwig University of Freiburg
Bastian E. Rapp: Albert Ludwig University of Freiburg

Nature Communications, 2024, vol. 15, issue 1, 1-10

Abstract: Abstract Microstructured molds are essential for fabricating various components ranging from precision optics and microstructured surfaces to microfluidics. However, conventional fabrication technology such as photolithography requires expensive equipment and a large number of processing steps. Here, we report a facile method to fabricate micromolds based on a reusable photoresponsive hydrogel: Uniform micropatterns are engraved into the hydrogel surface using photo masks under UV irradiation within a few minutes. Patterns are replicated using polydimethylsiloxane with minimum feature size of 40 μm and smoothness of Rq ~ 3.4 nm. After replication, the patterns can be fully erased by light thus allowing for reuse as a new mold without notable loss in performance. Utilizing greyscale lithography, patterns with different height levels can be produced within the same exposure step. We demonstrate the versatility of this method by fabricating diffractive optical elements devices and a microlens array and microfluidic device with 100 µm wide channels.

Date: 2024
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DOI: 10.1038/s41467-024-50008-6

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