The objective of this research study is to develop a new microsystems fabrication methodology in which three-dimensional micron and nanometer-scale structures are directly formed by in situ pulling of fibers from drops of liquid polymer. With this concept only recently demonstrated by the group, the principal focus during the study will be to enhance and extend both the understanding and control of the fabrication of the suspended fiber structures. The study will include (1) fundamental measurements (including the development of new atomic force microscopy and extensional rheometry measurement methods) of the formation of nanofibers from liquid polymers (2) the fabrication of structures (e.g. fibers, superporous fibers, capillaries, networks) from a variety of functional polymers, polymer blends, copolymers, biopolymers, and other polymer-based materials and (3) building and evaluating the functionality of prototype devices (e.g. fluidic networks, evanescent optical couplers and electromechanical actuators) which are built from the suspended polymer structures. The most significant broad impact of this project will be the development of an enabling nanofabrication technology that will allow laboratories around the world to construct with greater ease and lower cost, prototype nanostructures and devices from liquid polymers without the need for traditional microfabrication methods. A highlight of the effort is the team inter-laboratory interactions (including visits by graduate students to each other's laboratories) which are designed to increase access to specialized tools at each institution, broaden interdisciplinary experiences of the team members and students, and overall, foster a research environment that stimulates innovation, creativity and exploration of new ideas.
