Microscale Rapid Prototyping

Melissa Appel

Eric Dávila

Andrew Maclennan

Overview

• Review of Last Presentation– Purpose– Modeling the Scale Structures

• Progress

• Future Work

Purpose

• To Discover More about Butterfly Wings by Modeling Their Scale Structures

lower lamina

ridges

crossrib

lamellae

upper lamina

~0.5 m

scale cross section

–How they Trap Heat

–How they Display Colors

Modeling the Scale 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

Progress

• “Fixed” the SU-8, FSC Interaction Problem

• Better Way of Aligning Cure Pattern (Bottom Light)

• Took Pictures at an Angle

• Further Improved LabVIEW VI’s

• Offset for UV Curing

• New Ideas For Creation of Overhang

“Fixed” SU-8, FSC Interaction

• Problem: SU-8, When Not Cured, Dissolves FSC

“Fixed” SU-8, FSC Interaction

• Solution: One of Them Has to Go– Use SU-8 for Thick Column

• SU-8 Is Still Best for High Aspect Ratio

– Use Norland Optical Adhesive 81 for Layers between FSC

• NOA 81 Does Not Dissolve the FSC

Aligned Cure Pattern

• Problem: Hard To Align Multiple Patterns

Aligned Cure Pattern

• Solution: View Both Existing Pattern and Spot Light

» To Cure: Shine Light Through the Spotlight from the Top

» To See the Sample, Transmit Light from the Bottom

Eyepiece

Objectives

Sample holder stage

Focus wheel

Illumination forreflection

Illumination fortransmission

Took Pictures at an Angle

normal incidence 35 degree tilt 75 degree tilt

70 m

Further Improved LabVIEW VI’s

• Minimize Backlash– Slowed Ramp Rate– Slowed Pre-Run Speed

• Made Software Run Faster

Offset For UV Curing

• UV Light Has a Different Focal Length than White Light

Z Focal Offset: 21Line thickness: 26 m

Z Focal Offset: 15Line thickness: 22 m

Z Focal Offset: 9Line thickness: 17 m

New Ideas for Overhang

• Eat Away

• Diving Board

• Theme Day

Eat Away

• Spin and Cure 3 Layers: SU-8, FSC, NOA81

• Develop: Timing for “Eat Away” of FSC

Diving Board

Spin a Layer of FSC, with Tape

FSC Tape

Remove Tape

Spin and Cure NOA81

Develop to Remove FSC

Future Work

• Still Working on Overhang