In this work we present a novel microfabrication process that is based on combined use of dielectrophoresis (DEP) to
attract particles or cells to electrodes and to follow this step by an electrodeposition of polypyrrole (PPy) to entrap the
particles or cells on electrode surface. This process can be used for mass-production of high surface area structures as
well as to the creation of functionally graded materials. DEP was employed to pull the microparticles toward the surface
of the electrodes and hold them in place while PPy was electrodeposited. Polystyrene microbeads with diameters ranging
from 1 to 10 microns were employed in this study. Experimental results demonstrated that PPy can entrap the particles
attracted to the electrode surface by the positive DEP. It was also demonstrated that hierarchical structures can be created
where smaller microbeads are attached to, caught and secured on the surface of larger microbeads entrapped on the
electrode surface. Furthermore, as DEP can be employed for manipulating of wide variety of polarizable materials, this
process can also entrap inorganic and biological microparticles in the fabricated structure. Applications of this work
include, but are not limited to, the development of biomedical, electrokinetic, and energy storage devices,
electrochemical sensors, and scaffolds.
Polypyrrole (PPy)-based microactuators hold a promise for a wide variety of engineering applications from robotics and
microassembly to biosensors and drug delivery systems. The main advantages of using PPy/Au actuator structures (vs
competing solid-state actuator technologies) include ease of fabrication, low actuation energy, and large motion range of
microactuators. We present advances in two areas of application - in the extended-life biosensor platform and in
micromixers.
High specific surface area structures are used in a variety of applications including production of highly sensitive
biosensors, fabrication of separation membranes, manufacturing of high throughput catalytic microreactors, and
development of efficient electrodes for batteries and fuel cells. In many electrochemical applications (i.e. sensors and
batteries) it's also critical to have good conductive properties of the fabricated high surface area structures.
For energy harvesting technologies such as batteries and fuel cells, careful design of surface-to-volume ratio of the
electrode surface is important, because while high specific surface area facilitates electrochemical reaction rates, it also
increases overall electrode resistance. Thus, it is desirable to construct electrodes with a range of hierarchical features
(for example with fractal structures).
We invented a novel fabrication technology for creating three-dimensional conductive high surface area structures based
on the deposition and subsequent processing of the electroactive polymers (EAP). The proposed fabrication technique is
capable of fast and inexpensive production of high surface area structures with the designed geometry, porosity, and
conductivity.
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