Casimir force densities, i.e., force per area, become very large if two solid material surfaces come closer together to each other than 10 nm. In most cases, the forces are attractive. In some cases, they can be repulsive depending on the solid materials and the fluid medium in between. This review provides an overview of experimental and theoretical studies that have been performed and focuses on four main aspects: (i) the combinations of different materials, (ii) the considered geometries, (iii) the applied experimental measurement methodologies and (iv) a novel self-assembly methodology based on Casimir forces. Briefly reviewed is also the influence of additional parameters such as temperature, conductivity, and surface roughness. The Casimir effect opens many application possibilities in microelectromechanical systems (MEMS) and nanoelectromechanical systems (NEMS), where an overview is also provided. The knowledge generation in this fascinating field requires interdisciplinary approaches to generate synergetic effects between technological fabrication metrology, theoretical simulations, the establishment of adequate models, artificial intelligence, and machine learning. Finally, multiple applications are addressed as a research roadmap.

This work provides an overview on micromirror arrays based on different material systems such as dielectrics, element silicon, compound semiconductors, metals, and novel 2D materials. The goal is to work out the particular strength of each material system to enable optimum performance for various applications. In particular, this review is intended to draw attention to the fact that MEMS micro-mirrors can be successful in many other material systems besides silicon. In particular, the review is intended to draw attention to two material systems that have so far been used less for MEMS micromirror arrays, that have been less researched, and of which fewer applications have been reported to date: metallic heterostructures and 2D materials. However, the main focus is on metallic MEMS micromirror arrays on glass substrates for applications like personalized light steering in buildings via active windows, energy management, active laser safety goggles, interference microscopy, and endoscopy. Finally, the different micromirror arrays are compared with respect to fabrication challenges, switching speed, number of mirrors, mirror dimensions, array sizes, miniaturization potential for individual mirrors, reliability, lifetime, and hinge methodology.

For different metals and varying geometries, this paper presents simulations of electrostatically actuated MEMS cantilevers regarding their influence on pull-in voltage and actuation speed. Three-dimensional electromechanical modeling including many non-linearities has been performed to study some static but mainly dynamic features. The results show that the involved parameters have different influences on the actuation speed and pull-in voltage: lower length, higher thickness as well as lower density and higher Young’s modulus of material diminish the actuation time, while longer length, smaller thickness, and smaller Young’s modulus reduce the actuation voltages. Shorter actuation times and smaller actuation voltages cannot be obtained and optimized simultaneously. Different metals such as Au, Ag, Cu, Ti, Ni, Al, W, Cr, Ta, and Mo as well as artificial metals are studied and compared. In this study, Al is found to be the best material for achieving shorter actuation times and smaller actuation voltages. The design rules of MEMS cantilevers are derived considering the large variety of studied parameters. Many involved non-linearities are discussed in detail influencing the MEMS dynamics. Finally, the actuation times are related to the existing experimental actuation times of optical MEMS shutters and MEMS cantilevers.

For the 3D self-assembly of microstructures, the net intrinsic stress within a hybrid metal layer stack is utilised to study the dynamics of the pairing of metallic MEMS shutter blades with dimensions of 150 × 400 µm², representing a highly nonlinear Casimir system. The study focuses on two main geometries: (i) unpaired (freestanding) and (ii) paired metallic Micro-Electro-Mechanical Systems (MEMS) shutter blades. The hybrid metal stack comprises three metal layers that are under intrinsic stress, which enables the curling of the freestanding shutter blades. The top aluminum layer thickness is varied systematically, creating tailored stress in the shutter blades, resulting in the freestanding blades curling differently, as well as geometrical changes in the paired shutter blades. Concerning the thickness variations, a large technological processing window has been identified, during which the pairing of the neighbouring shutter blades occurs (the top aluminum layer thickness ranges between 70 and 88 nm). Circles and ellipses have been fitted to micrographs obtained by scanning electron microscopy (SEM) and Confocal Laser Scanning Microscopy (CLSM). We observed a trend of the reduction of the radius of curvature RoC (ranging between 17 and 79 µm) for the unpaired shutters, and eccentricity (0.36 < ε < 0.67) occurs throughout the system for the paired shutters. Concerning the specific shape of the overlapping region of the two blades of the paired shutters, three pairing scenarios (I, II, and III) have been identified, classified, evaluated, and reported. The overlapping length l_o between the paired shutter blades ranges between 31 and 8 µm. These scenarios also reveal nonlinearities in the pairing process.

We present a MEMS array-based approach for micro-irises called “ring shutter”, utilizing subfield addressing for applications in advanced micro-optics, such as interference microscopy. This experimental study is focused on investigating the homogeneity of electro-mechanical and optical characteristics within and between subfields of a lab demonstrator device. The characterization aims to ensure crosstalk-free and swift optical performance, as demonstrated in a previous study. For this purpose, the transmission in the initial state, actuation voltages, and response dynamics are measured for each electrode and the entire device, and the results are thoroughly compared. The measurements are conducted by expanding an existing optical actuation setup via tailored 3D-printed apertures, to isolate selected rings and zones. Evaluation of measurement data confirms the stable and crosstalk-free operation of the ring shutter. Both angular and radial homogeneity are robust and follow the expectations in the experiment. While transmission, actuation voltage and closing time slightly rise (up to 25%) with increased radial position represented by five discrete ring sections, the characteristics for different angular zones remain nearly constant. Response times are measured below 40 µs, actuation voltages do not exceed 60 V, and the overall transmission of the ring shutter yields 53.6%.

An innovative glass substrate surface technology including integrated micro-electro-mechanical systems (MEMS) is presented as an advanced light modulation, heat control, and energy management system. This smart technology is based on millions of metallic micromirrors per square meter fabricated on the glass surface, which are arranged in arrays and electrostatically actuated. The smart window application exploits an elaborate MEMS glass technology for active daylight steering and energy management in buildings, enabling energy saving, CO₂ emission reduction, a positive health impact, and improved well-being. When light interacts with a glass substrate that has regular, repetitive patterning at the microscopic scale on its surface, these microstructures can cause the diffraction of the transmitted light, resulting in the potential deterioration of the view quality through the smart glass. A reduction in optical artifacts for improved clear view is presented by using irregular geometric micromirror apertures. Several non-periodic, irregular micromirror aperture designs are compared with corresponding periodic regular designs. For each considered aperture geometry, the irregular array reveals a reduction in optical artifacts and, therefore, by far a clearer view than the corresponding regular array. A systematic and comprehensive study was conducted through design, simulation, technological fabrication, experimental characterization, and analysis.