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.

The paper presents the design and technological fabrication process of Yin or Yang-shaped, micron-sized electromechanical system (MEMS) elements displaying asymmetric hollow cylinders with two different curvatures of the cylinder shell. By adapting the process steps, two neighboring shutter MEMS elements can either be attached to each other to create asymmetric hollow cylinders or remain disconnected to form curled cylindrical or ellipsoidal tubes or tube fractions. A novel 3D self-organization process has been developed to connect two neighboring shutter elements, exploiting surface tension forces via a sequential drying process. The process conditions have been analyzed and optimized to fabricate the two different geometries of the MEMS elements. The resulting MEMS system elements were characterized by focused ion beam and scanning electron microscopy. The contribution of Casimir force, van der Waals force, and other physical interfacial forces are discussed in the formation of the asymmetric hollow cylinders.

This study demonstrates the use of coherence scanning interferometry for high-precision surface deviation measurements, focusing on differential topography analysis. Two approaches are explored: adaptive interferometry with automated sample alignment and a conventional method using 2D cross-correlation for topography evaluation. Using the Circle Hough Transform and piezo-actuated positioning systems, precise sample alignment is achieved, significantly improving measurement accuracy and reducing the time-consuming manual alignment process. For surfaces with complex structures, such as grating imprints, the 2D cross-correlation method effectively determines lateral shifts and differential topographies. The results demonstrate that both methods are effective in identifying and quantifying surface deviations, offering a robust solution for quality control in mass production scenarios.

Homologues of benzophenone silane, a covalently graftable, photochemically active surface functionalizing agent, are investigated as surface functionalization agents for both small particles and planar substrates.