Surface Molding of Microscale Hydrogels with Microactuation Functionality

This work describes the fabrication of numerous hydrogel microstructures (μ‐gels) via a process called “surface molding.” Chemically patterned elastomeric‐assembly substrates were used to organize and manipulate the geometry of liquid prepolymer microdroplets, which, following photo‐initiated crosslinking, maintained the desired morphology. By adjusting the state of strain during the crosslinking process, a continua of structures could be created using one pattern. These arrays of μ‐gels have stimuli‐responsive properties that are directly applicable to actuation where the basis shape and array geometry of the μ‐gels can be used to rationally generate microactuators with programmed motions. As a method, “surface molding,” represents a powerful addition to the soft‐lithographic toolset that can be readily applied to the simultaneous synthesis of large numbers of geometrically and functionally distinct polymeric microstructures. Surface molding uses chemically patterned, elastomeric‐assembly substrates to organize and manipulate prepolymer microdroplets enabling the synthesis of arrays of geometrically distinct polymeric microstructures. The hydrogel microstructures (μ‐gels) have stimuli‐responsive properties directly applicable to the preparation of soft actuators with programmable motions.