Abstract: A selected surface of the present disclosure is characterized by a two-tier nanostructure: first-tier nanostructures and second-tier nanostructures disposed on at least a cell wall of the first-tier nanostructures. The first-tier nanostructures define a network of cells, each with a cell wall and a recessed core. The core is predominantly formed of a first phase of an additively formed aluminum alloy, and the cell wall is predominantly formed of a second phase of the same additively formed aluminum alloy. A method of forming the two-tier nanostructure includes preferential etching of the core over the cell wall to form a network of open cells, and a self-limiting formation of the second-tier nanostructure to form a plurality of sub-cavities characterized by nanoscale dimensions smaller than the cell opening of a cell.

Abstract: A microfluidic diagnostic device with a three-dimensional (3D) flow architecture comprises a polymeric body having first and second opposing surfaces and comprising first flow channels in the first opposing surface, second flow channels in the second opposing surface, and connecting flow passages extending through a thickness of the polymeric body to connect the first flow channels to the second flow channels, thereby defining a continuous 3D flow pathway in the polymeric body. The microfluidic diagnostic device also includes a first cover adhered to the first opposing surface to seal the first flow channels, a second cover adhered to the second opposing surface to seal the second flow channels, and one or more access ports in fluid communication with the continuous 3D flow pathway for introducing liquid reagent(s) and/or a sample into the polymeric body.

Abstract: An active thermal management system for electronic devices comprises: a heat spreader having an internal channel; a thermally conductive body moveably positioned in the internal channel; and two or more electronic devices in thermal contact with a back surface of the heat spreader and positioned adjacent to the internal channel. A location of the thermally conductive body within the internal channel determines a path for heat flow from the back surface to a front surface of the heat spreader. The location of the thermally conductive body within the internal channel may be selected to minimize a temperature differential (?T) between the electronic devices.

Abstract: A microfluidic diagnostic device with a three-dimensional (3D) flow architecture comprises a polymeric body having first and second opposing surfaces and comprising first flow channels in the first opposing surface, second flow channels in the second opposing surface, and connecting flow passages extending through a thickness of the polymeric body to connect the first flow channels to the second flow channels, thereby defining a continuous 3D flow pathway in the polymeric body. The microfluidic diagnostic device also includes a first cover adhered to the first opposing surface to seal the first flow channels, a second cover adhered to the second opposing surface to seal the second flow channels, and one or more access ports in fluid communication with the continuous 3D flow pathway for introducing liquid reagent(s) and/or a sample into the polymeric body.

Abstract: An active thermal management system for electronic devices comprises: a heat spreader having an internal channel; a thermally conductive body moveably positioned in the internal channel; and two or more electronic devices in thermal contact with a back surface of the heat spreader and positioned adjacent to the internal channel. A location of the thermally conductive body within the internal channel determines a path for heat flow from the back surface to a front surface of the heat spreader. The location of the thermally conductive body within the internal channel may be selected to minimize a temperature differential (?T) between the electronic devices.

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: Provided herein are electron emission devices and device components for optical, electronic and optoelectronic devices, including cantilever-based MEMS and NEMS instrumentation. Devices of certain aspects of the invention integrate a dielectric, pyroelectric, piezoelectric or ferroelectric film on the receiving surface of a substrate having an integrated actuator, such as a temperature controller or mechanical actuator, optionally in the form of a cantilever device having an integrated heater-thermometer. Also provided are methods of making and using electron emission devices for a range of applications including sensing and imaging technology.

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: A method of making a three-dimensional porous device entails providing a substrate having a conductive pattern on a surface thereof, and depositing a colloidal solution comprising a plurality of microparticles onto the surface, where the microparticles assemble into a lattice structure. Interstices of the lattice structure are infiltrated with a conductive material, which propagates through the interstices in a direction away from the substrate to reach a predetermined thickness. The conductive material spans an area of the surface overlaid by the conductive pattern. The microparticles are removed to form voids in the conductive material, thereby forming a conductive porous structure having the predetermined thickness and a lateral size and shape defined by the conductive pattern.

Abstract: A three-dimensional porous electrode architecture for a microbattery includes a substrate having first and second conductive patterns disposed thereon where the first and second conductive patterns are electrically isolated from each other, a three-dimensional porous cathode disposed on the first conductive pattern, and a three-dimensional porous anode disposed on the second conductive pattern. The porous cathode includes a first conductive scaffold conformally coated with a layer of a cathode active material and having a porosity defined by a network of interconnected pores, where the first conductive scaffold has a lateral size and shape defined by the first conductive pattern and porous side walls oriented substantially perpendicular to the substrate. The porous anode includes a second conductive scaffold conformally coated with a layer of an anode active material and having a porosity defined by a network of interconnected pores.

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: In one aspect, provided herein is a single crystal silicon microcalorimeter, for example useful for high temperature operation and long-term stability of calorimetric measurements. Microcalorimeters described herein include microcalorimeter embodiments having a suspended structure and comprising single crystal silicon. Also provided herein are methods for making calorimetric measurements, for example, on small quantities of materials or for determining the energy content of combustible material having an unknown composition.

Abstract: Described are methods for magnetically actuating microcantilevers and magnetically actuated and self-heated microcantilevers. Also described are methods for determining viscoelastic properties and thermal transition temperatures of materials.

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: Provided herein are electron emission devices and device components for optical, electronic and optoelectronic devices, including cantilever-based MEMS and NEMS instrumentation. Devices of certain aspects of the invention integrate a dielectric, pyroelectric, piezoelectric or ferroelectric film on the receiving surface of a substrate having an integrated actuator, such as a temperature controller or mechanical actuator, optionally in the form of a cantilever device having an integrated heater-thermometer. Also provided are methods of making and using electron emission devices for a range of applications including sensing and imaging technology.

Abstract: A three-dimensional porous electrode architecture for a microbattery includes a substrate having first and second conductive patterns disposed thereon where the first and second conductive patterns are electrically isolated from each other, a three-dimensional porous cathode disposed on the first conductive pattern, and a three-dimensional porous anode disposed on the second conductive pattern. The porous cathode includes a first conductive scaffold conformally coated with a layer of a cathode active material and having a porosity defined by a network of interconnected pores, where the first conductive scaffold has a lateral size and shape defined by the first conductive pattern and porous side walls oriented substantially perpendicular to the substrate. The porous anode includes a second conductive scaffold conformally coated with a layer of an anode active material and having a porosity defined by a network of interconnected pores.