Cost-efficient microstructured surfaces through Microfold

TO-202 • PT 1.2894 • As of 01/2025
Institute for Advances Simulation (IAS)
Theoretical Physics of Living Matter (IAS-2)

Technology

The properties of surfaces play a decisive role in countless products and manufacturing processes. The aim of surface technologies is to change and functionalise surface properties, which is achieved, for example, by creating geometrically and topographically structured surfaces. They play an important role in almost all manufacturing processes, from the metalworking industry to the semiconductor industry all the way up to biomedicine. Inspired by a scientific project on brain folding, we developed the idea of structuring surfaces of elastomers by controlling wrinkling patterns using masks. With our in-house HPC simulations, we are able to predict the structures resulting from particular masks. In this way, we can structure surfaces in a targeted manner and, for example, produce microfluidic chips or structured cell culture dishes. In addition to accelerated development cycles and lower costs due to less complex processes, our technology in particular enables novel functionalised and dynamic surfaces.

Problem addressed

The possibilities of current methods for structuring surfaces are either very limited (polishing, brushing, etc.) and/or very expensive (lithography, laser structuring, etc.). Highly regular and reproducable microstructures over large areas at affordable cost remain a major challenge for industry and development.

Solution

We offer a simple and cost-effective process to create microstructures. An elastomer like a silicone rubber or hydrogel is stretched. Using a mask, a well controlled part of the surface is hardened. Upon release, the elastomer-surface folds into a three dimensional microstructure. Thanks to our HPC-Computer simulations, this structure can be predicted, and thus masks for desired structures designed.

Benefits and Potential Use

Microstructured surfaces already have a very wide range of applications. The spectrum ranges from mechanical engineering to microelectronics, medical technology, automotive engineering and plastics processing, to building technology and architecture. Modern biotechnological applications such as lab-on-a-chip technologies also work with structured surfaces.

Development Status and Next Steps

The technology described above has already been initially verified through prototypes and is continuously being developed further. We are continuously seeking for cooperation partners and/or licensees in this and adjacent areas of research and applications.

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