Dan Sameoto

A review of piezoelectric polymers as functional materials for electromechanical transducers

Polymer based MEMS and microfluidic devices have the advantages of mechanical flexibility, lower fabrication cost and faster processing over silicon based ones. Also, many polymer materials are considered biocompatible and can be used in biological applications. A valuable class of polymers for microfabricated devices is piezoelectric functional polymers. In addition to the normal advantages of polymers, piezoelectric polymers can be directly used as an active material in different transduction applications. This paper gives an overview of piezoelectric polymers based on their operating principle. This includes three main categories: bulk piezoelectric polymers, piezocomposites and voided charged polymers. State-of-the-art piezopolymers of each category are presented with a focus on fabrication techniques and material properties. A comparison between the different piezoelectric polymers and common inorganic piezoelectric materials (PZT, ZnO, AlN and PMN?PT) is also provided in terms of piezoelectric properties. The use of piezopolymers in different electromechanical devices is also presented. This includes tactile sensors, energy harvesters, acoustic transducers and inertial sensors.

Recent advances in the fabrication and adhesion testing of biomimetic dry adhesives

In the past two years, there have been a large number of publications on the topic of biomimetic dry adhesives from modeling, fabrication and testing perspectives. We review and compare the most recent advances in fabrication and testing of these materials. While there is increased convergence and consensus as to what makes a good dry adhesive, the fabrication of these materials is still challenging, particularly for anisotropic or hierarchal designs. Although qualitative comparisons between different adhesive designs can be made, quantifying the exact performance and rating each design is significantly hampered by the lack of standardized testing methods. Manufacturing dry adhesives, which can reliably adhere to rough surfaces, show directional and self-cleaning behavior and are relatively simple to manufacture, is still very challenging—great strides by multiple research groups have however made these goals appear achievable within the next few years.

A low-cost, high-yield fabrication method for producing optimized biomimetic dry adhesives

We present a low-cost, large-scale method of fabricating biomimetic dry adhesives. This process is useful because it uses all photosensitive polymers with minimum fabrication costs or complexity to produce molds for silicone-based dry adhesives. A thick-film lift-off process is used to define molds using AZ 9260 photoresist, with a slow acting, deep UV sensitive material, PMGI, used as both an adhesion promoter for the AZ 9260 photoresist and as an undercutting material to produce mushroom-shaped fibers. The benefits to this process are ease of fabrication, wide range of potential layer thicknesses, no special surface treatment requirements to demold silicone adhesives and easy stripping of the full mold if process failure does occur. Sylgard® 184 silicone is used to cast full sheets of biomimetic dry adhesives off 4 diameter wafers, and different fiber geometries are tested for normal adhesion properties. Additionally, failure modes of the adhesive during fabrication are noted and strategies for avoiding these failures are discussed. We use this fabrication method to produce different fiber geometries with varying cap diameters and test them for normal adhesion strengths. The results indicate that the cap diameters relative to post diameters for mushroom-shaped fibers dominate the adhesion properties.

Abigaille ii: Toward the development of a spider-inspired climbing robot

This paper presents a novel robotic platform, Abigaille II, designed to climb vertical surfaces using dry adhesion. Abigaille II is a lightweight hexapod prototype actuated by 18 miniaturized motors. The robots feet consist of adhesive patches, which have microhairs with mushroom-shaped caps fixed on the top of millimeter-scale flexible posts. A pentapedal gait is used to climb flat vertical surfaces as this gait maximizes the number of legs in contact to the surface. Abigaille can however also walk by using other gaits, including the tripod gait.

Deep UV patterning of acrylic masters for molding biomimetic dry adhesives

We present a novel fabrication method for the production of biomimetic dry adhesives that allows enormous variation in fiber shapes and sizes. The technology is based on deep-UV patterning of commercial acrylic with semi-collimated light available from germicidal lamps, and combined careful processing conditions, material selection and novel developer choices to produce relatively high-aspect-ratio fibers with overhanging caps on large areas. These acrylic fibers are used as a master mold for subsequent silicone rubber negative mold casting. Because the bulk acrylic demonstrates little inherent adhesion to silicone rubbers, the master molds created in this process do not require any surface treatments to achieve high-yield demolding of interlocked structures. Multiple polymers can be cast from silicone rubber negative molds and this process could be used to structure smart materials on areas over multiple square feet. Using direct photopatterning of acrylic allows many of the desired structures for biomimetic dry adhesives to be produced with relative ease compared to silicon-based molding processes, including angled fibers and hierarchical structures. Optimized fiber shapes for a variety of polymers can be produced using this process, and adhesion measurements on a well-characterized polyurethane, ST-1060, are used to determine the effect of fiber geometry on adhesion performance.

Multi-Scale Compliant Foot Designs and Fabrication for Use with a Spider-Inspired Climbing Robot

Climbing robots are of potential use for surveillance, inspection and exploration in different environments. In particular, the use of climbing robots for space exploration can allow scientists to explore environments too challenging for traditional wheeled designs. To adhere to surfaces, biomimetic dry adhesives based on gecko feet have been proposed. These biomimetic dry adhesives work by using multi-scale compliant mechanisms to make intimate contact with different surfaces and adhere by using Van der Waals forces. Fabrication of these adhesives has frequently been challenging however, due to the difficulty in combining macro, micro and nanoscale compliance. We present an all polymer foot design for use with a hexapod climbing robot and a fabrication method to improve reliability and yield. A high strength, low-modulus silicone, TC-5005, is used to form the foot base and microscale fibres in one piece by using a two part mold. A macroscale foot design is produced using a 3D printer to produce a base mold, while lithographic definition of microscale fibres in a thick photoresist forms the ‘hairs’ of the polymer foot. The adhesion of the silicone fibres by themselves or attached to the macro foot is examined to determine best strategies for placement and removal of feet to maximize adhesion. Results demonstrate the successful integration of micro and macro compliant feet for use in climbing on a variety of surfaces.

Controllable biomimetic adhesion using embedded phase change material

In many cases, such as in the instance of climbing robots or temporary adhesives, there is the need to be able to dynamically control the level of adhesion a biomimetic dry adhesive can provide. In this study, the effect of changing the backing layer stiffness of a dry adhesive is examined. Embedding a phase change material within the backing of a synthetic dry adhesive sheet allows the stiffness to be tailored at different points of a preload and adhesion cycle. Larger contact areas and more equal load sharing between adhesive fibres can be achieved by increasing the backing layer stiffness after initial deformation when the adhesive backing is loaded in its softened state. Adhesion behaviour is examined when the backing layer is maintained in solid and softened phases during complete load cycles and for load cycles under the condition of contact with the softened phase backing followed by pull-off during the solid phase. Absolute adhesion force is increased for trials in which a soft backing layer hardens prior to pull-off. This effect is due to the increased contact area made between the rounded probe and the softened material during preloading and the more equal load sharing condition during pull-off when the backing layer becomes stiff again.

Deep-UV patterning of commercial grade PMMA for low-cost, large-scale microfluidics

Although PMMA can be exposed using a variety of exposure sources, deep-UV at 254 nm is of interest because it is relatively inexpensive. Additionally, deep-UV sources can be readily scaled to large area exposures. Moreover, this paper will show that depths of over 100µm can be created in commercial grade PMMA using an uncollimated source. These depths are sufficient for creating microfluidic channels. This paper will provide measurements of the dissolution depth of commercial grade PMMA as a function of the exposure dose and etch time, using an IPA:H2O developer. Additionally, experiments were run to characterize the dependence of the dissolution rate on temperature and agitation. The patterned substrates were thermally bonded to blank PMMA pieces to enclose the channels and ports were drilled into the reservoirs. The resulting fluidic systems were then tested for leakage. The work herein presents the patterning, development and system behaviour of a complete microfluidics system based on commercial grade PMMA.

Abigaille-I: Towards the development of a spider-inspired climbing robot for space use

This paper presents the design and testing of Abigaille-I, a spider-inspired robot. The system is miniaturized and has six legs and 18 actively controlled joints. Macro-, micro- and nano-structural design of the robot legs and feet are presented and preliminary experimental results are discussed. The long-term objective of this research is to develop an autonomous and miniaturized robotic system capable to negotiating terrain of any roughness and material and be eventually capable of operating in a space environment.

Microwave-induced, thermally assisted solvent bonding for low-cost PMMA microfluidic devices

We present a low-cost bonding method for polymethylmethacrylate (PMMA) microfluidics that combines elements of solvent bonding, thermal bonding and microwave bonding. Rather than using specialized equipment, we take household equipment and combine it to produce an effective bonding method that borrows from food packaging technologies for selective heating in a microwave. A poor solvent for PMMA is applied between two halves of a microfluidic system and clamped together using miniature binder clips. Excess solvent from the channels is then drawn out via capillary action and avoids channel clogging during the bonding process. Placing the whole apparatus in a commercial microwave will heat up the thin metal clips and cause the solvent to dissolve and bond the PMMA interface. The whole bonding process takes only a few minutes, and results in high bond strengths.