(236a) Preprogrammed Noncontact Patterning of Polymer Films

Many contact and non-contact methods have been developed over the years for the formation of three-dimensional topography in polymer films. Some of these techniques include electrohydrodynamic patterning, where pattern formation relies on an electric field applied to a dielectric polymer film and lithographically induced self-assembly, which exploits close proximity of a liquid polymer film to a patterned template. In these methods, the patterned template is placed a controlled distance away from the polymer film throughout the entire topography development process, which inherently limits throughput. These techniques are often slow, sometimes requiring hours for the pattern to fully develop with polymer melts. Alternatively, contact methods, such as micro-contact printing or imprint lithography, utilize ‘stamps’ or templates to directly transfer a relief pattern into a polymer film. Here we describe a new non-contact strategy for high-speed patterning of arbitrary shapes in polymer films. In this approach, the topographical pattern can be preprogrammed and stored in a smooth solid film, and later revealed without use of a wet or dry etch step, unlike traditional photoresist methods. Micro- and nano-scale features created by this method could be used for facile creation of soft-lithographic stamps, microfluidic devices or roll-to-roll manufacturing of textured surfaces for anti-biofouling coatings.