Abstract: A method and surface micro patterned stamp for patterning image correlation test specimens is disclosed. The stamp may be formed and applied to the surface of structural components and laboratory test specimens in a repeatable fashion while reducing requisite infrastructure and time. The resulting test specimen incorporating the surface micro stamped pattern is also disclosed.

Abstract: This invention is directed to a microstructured filament that can be used to make fibers having an extruded filament having pre-cooled microfeatures in a radial spiral arrangement about a bore though the filament wherein the microfeature has a width in the range of 25 ?m to 40 ?m and height in the range of 90 ?m to 100 ?m; and, the filament having a post-cooled state having post-cooled microfeatures having physical dimensions smaller than that of the pre-cooled microfeatures. The filament can include microfeatures having a width in the range of 400 nm to 4 ?m and height in the range of 400 nm to 4 ?m. The filament and fiber can include physical characteristics selected from the group consisting of: hydrophobicity, self-cleaning, increased hydro-dynamic drag coefficients, decreased or increased aerodynamic drag coefficients, increased friction, reduced friction, optical effects, increased adhesion, decreased adhesion, oleophobicity, tactile effects, anti-blocking and any combination of these.

Abstract: Described herein are flexible superhydrophobic films. Also described are methods for imparting superhydrophobicity to a variety of objects, for example objects having any shape or surface contours. For specific applications, the flexible superhydrophobic films include an adhesive backing layer, useful for attaching the film to objects. Some of the films described herein allow for selective control over the wettability of a surface by flexing the film, for example flexing the film results in a more wettable film, a less wettable film or a film having unchanged wettability. Flexible superhydrophobic films described herein also include films which maintain their superhydrophobicity when deformed into a concave or convex curvature.

Abstract: Described herein are casting and molding methods useful for making microstructured objects. By including a plurality of microfeatures on the surface of an object, other characteristics may be imparted to the object, such as increased hydrophobicity. Some of the casting and molding methods described herein further allow for manufacture of objects having both microfeatures and macro features, for example microfeatures on or within macro features or selected macro feature regions.

Abstract: This invention is directed to a microstructured filament that can be used to make fibers having an extruded filament having pre-cooled microfeatures in a radial spiral arrangement about a bore though the filament wherein the microfeature has a width in the range of 25 ?m to 40 ?m and height in the range of 90 ?m to 100 ?m; and, the filament having a post-cooled state having post-cooled microfeatures having physical dimensions smaller than that of the pre-cooled microfeatures. The filament can include microfeatures having a width in the range of 400 nm to 4 ?m and height in the range of 400 nm to 4 ?m. The filament and fiber can include physical characteristics selected from the group consisting of: hydrophobicity, self-cleaning, increased hydro-dynamic drag coefficients, decreased or increased aerodynamic drag coefficients, increased friction, reduced friction, optical effects, increased adhesion, decreased adhesion, oleophobicity, tactile effects, anti-blocking and any combination of these.

Abstract: A manufacturing apparatus for manufacturing extruded parts having microstructures comprising: a support structure; a hopper carried by the support structure for receiving feedstock; an extrusion chamber operatively associated with the hopper for receiving the feedstock from the hopper and melting the feedstock above a feedstock melting temperature; a die carried by the support structure having die microstructures disposed on an inner surface of the die, the die microstructures having a plurality of microfeatures each having an upper surface and a lower surface, the melted feedstock being forced through the die to produce an extrudate having extrudate microstructures; and, a cooling assembly wherein the extrudate microstructures of the pre-cooled extrudate have larger physical dimensions than that of the extrudate microstructures of the cooled extrudate.

Abstract: A manufacturing apparatus for manufacturing extruded parts having microstructures comprising: a support structure; a hopper carried by the support structure for receiving feedstock; an extrusion chamber operatively associated with the hopper for receiving the feedstock from the hopper and melting the feedstock above a feedstock melting temperature; a die carried by the support structure having die microstructures disposed on an inner surface of the die, the die microstructures having a plurality of microfeatures each having an upper surface and a lower surface, the melted feedstock being forced through the die to produce an extrudate having extrudate microstructures; and, a cooling assembly wherein the extrudate microstructures of the pre-cooled extrudate have larger physical dimensions than that of the extrudate microstructures of the cooled extrudate.

Abstract: A manufacturing apparatus for manufacturing extruded parts having microstructures comprising: a support structure; a hopper carried by the support structure for receiving feedstock; an extrusion chamber operatively associated with the hopper for receiving the feedstock from the hopper and melting the feedstock above a feedstock melting temperature; a die carried by the support structure having die microstructures disposed on an inner surface of the die, the die microstructures having a plurality of microfeatures each having an upper surface and a lower surface, the melted feedstock being forced through the die to produce an extrudate having extrudate microstructures; and, a cooling assembly wherein the extrudate microstructures of the pre-cooled extrudate have larger physical dimensions than that of the extrudate microstructures of the cooled extrudate.

Abstract: The method for manufacturing products having a metal surface by imparting microfeatures onto the metal surface. The method if further described as the steps of: creating a transfer tool from a microstructured intermediate fabricated from a microstructured prototype having microfeatures; and, transferring the microfeatures to said metal surface using the transfer tool.

Abstract: A manufacturing apparatus for manufacturing extruded parts having microstructures comprising: a support structure; a hopper carried by the support structure for receiving feedstock; an extrusion chamber operatively associated with the hopper for receiving the feedstock from the hopper and melting the feedstock above a feedstock melting temperature; a die carried by the support structure having die microstructures disposed on an inner surface of the die, the die microstructures having a plurality of microfeatures each having an upper surface and a lower surface, the melted feedstock being forced through the die to produce an extrudate having extrudate microstructures; and, a cooling assembly wherein the extrudate microstructures of the pre-cooled extrudate have larger physical dimensions than that of the extrudate microstructures of the cooled extrudate.

Abstract: Described are methods for making microstructured flexible molds, for example useful for making microstructured metal objects in a casting process. Also described are casting methods for making microstructured epoxy objects. In some embodiments, the microstructured metal and epoxy objects are useful for embossing polymer sheets to form microstructured polymer sheets.

Abstract: Described herein are flexible superhydrophobic films. Also described are methods for imparting superhydrophobicity to a variety of objects, for example objects having any shape or surface contours. For specific applications, the flexible superhydrophobic films include an adhesive backing layer, useful for attaching the film to objects. Some of the films described herein allow for selective control over the wettability of a surface by flexing the film, for example flexing the film results in a more wettable film, a less wettable film or a film having unchanged wettability. Flexible superhydrophobic films described herein also include films which maintain their superhydrophobicity when deformed into a concave or convex curvature.

Abstract: Described herein are casting and molding methods useful for making microstructured objects. By including a plurality of microfeatures on the surface of an object, other characteristics may be imparted to the object, such as increased hydrophobicity. Some of the casting and molding methods described herein further allow for manufacture of objects having both microfeatures and macro features, for example microfeatures on or within macro features or selected macro feature regions.

Abstract: A method of manufacturing a production part having microstructured features comprising the steps of fabricating a microstructured prototype having microstructured features, manufacturing a microstructured intermediate from the microstructured prototype so that the microstructured intermediate carries a negative of the microstructured features, attaching the microstructured intermediate to a manufacturing tool thereby providing microstructured features on a manufacturing tool, providing feedstock containing material from the group comprising of: metal, ceramic, binder, and any combination of these and manufacturing the production part from the feedstock, using the manufacturing tool and using a process from the group consisting of: compression molding, roll forming, stamping, embossing, extrusion injection molding, and any combination of these.

Abstract: The method for manufacturing products having a metal surface by imparting microfeatures onto the metal surface. The method if further described as the steps of: creating a transfer tool from a microstructured intermediate fabricated from a microstructured prototype having microfeatures; and, transferring the microfeatures to said metal surface using the transfer tool.