Micropatterning of fluoropolymers

Fluoropolymer (PTFE and FEP) substrates have been patterned through micro-contact printing of an aminosilane. The silane pattern was activated with a palladium catalyst that allowed the electroless deposition of copper which was used to form micropatterned copper electrodes. Conducting polymer micropatterns were then fabricated by electrodeposition of polypyrrole (PPy) onto the copper. The resulting patterns of 80 mm and 10 mm grids and 2 mm and 5 mm checkerboards were characterized using imaging XPS, TOF-SIMS, AFM and SEM. The size and resolution of the smallest copper patterns were limited by the copper grain size created during electroless deposition. The polypyrrole patterns were also limited by the roughness of the electrolytically deposited polymer film.