micro-scale rapid prototyping melissa appel eric dávila andrew maclennan

Micro-scale Rapid Prototyping

Melissa Appel

Eric Dávila

Andrew Maclennan

Overview

Background

Purpose

Prior Work

Experimental Setup

Improvements Needed

What We’ve Done

Future Work

But First…

What’s the difference between a

Moose

and an

Ant?

Give Up?

A Moose has Antlers, but an Ant doesn’t have Mooselers!

We apologize for the preceding slides. Those responsible have

been sacked.

And Now On With the Show…

Background

Butterflies Butterflies’

wings have millions of scales, each of which has hundreds of structures on its upper surface.

ridges

crossrib

lamellae

lower lamina

upper lamina

~0.5 m

scale cross section

Purpose

To Discover More about Butterfly Wings

How they Trap Heat

How they Display Colors

thin film

air

airsubstrate

incident radiation reflected radiation

transmitted radiation

Prior Work

Microscope Setup

CCD or photodiode

Field limiting aperture

Eyepiece

Objectives

Sample holder stage

Focus wheel

Iris & field diaphragm

Illumination forreflection

Illumination fortransmission

Photometry view port

Modeling these Structures

Single Layer Structure Spin out a Thin Layer of

SU-8 on a Glass Slide Cure a Pattern in the

SU-8 Using UV Light Develop the Slide to

Wash Away Unexposed SU-8

Experimental Setup

Improvements Needed

Stage MovementSpin CoaterOptimize Thin Film Parameters Pre-baking Resist Application Curing Speeds for Better

Resolution Substrate: Glass or Silicon Developing Process

Multilayer Structures

X

Y -Into/out of page Plate

Stepper motor

Linear ball bearing slides

Micro-positioning stages

L brackets

Z

7.5”

7.5”

h = 0.1875”Cutout

Clamps

Simple support

Existing Stage

What We’ve Done

New Spin Coater

Optimized Thin Film Parameters

Built Multi-Layered Structures (we think)

“Huffed”

Catalogued Our Work

New Spin Coater

Slide Lies Flat

Air Circulation Minimized

Slide Removal Easier

Optimized Thin Film Parameters

Amount of Resist Placed on SlidePre-exposure Baking Air Bubbles Minimized

Curing Speeds for Better Resolution 1 & 5 Micron Films

Tried Silicon Wafers Washed Developer with Isopropyl Alcohol or Acetone

Built Multi-Layered Structures (we think)

The Great Pyramids:

…And Now, For Something Completely Different…

Our Plan For World Domination

Our Plan For Multilayer Construction

Spin Thick Layer of SU-8

Cure a Tall Column

Develop Negative Resist

Spin Alternating Layers of SU-8 and FSC

Cure All Layers

Develop All Cured ResistsUncured SU-8 and all FSC will be developed away.

Catalogued Our Work

Edited Existing LabVIEW VI’s

Using LabVIEWSnapped PicturesMeasured Line Thicknesses

Some Pictures

Slide: 1 Box: B film thickness: 1 m speed: X: 15, Y: 20 Objective: 50x

Line thickness: 20 m Line thickness: 20 m

X Y

More Pictures

Future Work

Improve the Stage

Thinner Lines

Multilayer Structures with Overhang

Take Pictures of Slides at an Angle

The “Working Hard” Slide