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The first step was the preparation of a silicon master pattern.
Micromolding processes are replication-based processes, involving feature-transferring mechanisms, e.g., injection, compression, casting and intrusion, for replicating the master pattern on a mold to a plastic material.
For large, heavy-gauge parts, thermoforming tools are typically made by CNC machining a billet of material or sand casting from an inexpensive master pattern.
The master pattern had hexagonal arrays of nanopillars, whose diameter and spacing between nearest neighbors were 150 and 300 nm, respectively.
The silicon master pattern was then replicated onto a polytetrafluoroethylene (PTFE) polymer stamp by UV nanoimprinting to obtain the inverse pattern profile (i.e., an array of nanopillars).
The Si master pattern was replicated on a polyurethane acrylate-based custom-made UV-curable resin (PUA) on a polyethylene terephthalate (PET) film, which was used as the NI mold.
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I studied proportions, fabrics and their properties, and I learned to master pattern-making.
These master patterning genes have immediately recognizable cousins in vertebrates like humans, although there are somewhat more of them.
Fig. 1 The top-down SEM images of silicon master, patterned ETFE mold, and P3HT nanograting film surface.
Examples of top-down SEM images of silicon master, patterned ETFE mold, and P3HT nanograting film surface are shown in Fig. 1, respectively, confirming that uniform arrays of P3HT nanogratings can be obtained by the SART-NIL method here.
Master patterns required for molding can be fabricated by e-beam [5], interference lithography [8, 9], anodizing aluminum oxide [10, 11], colloidal nanolithography using polystyrene [12 14], and electron cyclotron resonance (ECR) plasma etching [15, 16].
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