PMID- 34960911 OWN - NLM STAT- PubMed-not-MEDLINE LR - 20211230 IS - 2073-4360 (Electronic) IS - 2073-4360 (Linking) VI - 13 IP - 24 DP - 2021 Dec 13 TI - Design Rule for Constructing Buckling-Free Polymeric Stencil with Microdot Apertures. LID - 10.3390/polym13244361 [doi] LID - 4361 AB - A polymeric stencil with microdot apertures made by using polydimethylsiloxane (PDMS) molds with pillar patterns has many advantages, including conformal contact, easy processability, flexibility, and low cost compared to conventional silicon-based membranes. However, due to the inherent deformability of PDMS materials in response to external pressure, it is challenging to construct structurally stable stencils with high structural fidelity. Here, we propose a design rule on the buckling pressure for constructing polymeric stencils without process failure. To investigate the critical buckling pressure (P(cr)), stencils are fabricated by using different PDMS molds with aspect ratio variations (AR: 1.6, 2.0, 4.0, and 5.3). By observing the buckled morphology of apertures, the structures can be classified into two groups: low (AR 1.6 and 2.0) and high (AR 4.0 and 5.3) AR groups, and P(cr) decreases as AR increases in each group. To investigate the results theoretically, the analysis based on Euler's buckling theory and slenderness ratio is conducted, indicating that the theory is only valid for the high-AR group herein. Besides, considering the correction factor, P(cr) agrees well with the experimental results. FAU - Kim, Minju AU - Kim M AD - Department of Mechanical Engineering, Incheon National University, Incheon 22012, Korea. FAU - Lee, Jinwon AU - Lee J AD - Department of Mechanical Engineering, Incheon National University, Incheon 22012, Korea. FAU - Kim, Junsoo AU - Kim J AUID- ORCID: 0000-0001-7340-2770 AD - John A. Paulson School of Engineering and Applied Science, Harvard University, Cambridge, MA 02138, USA. FAU - Jang, Segeun AU - Jang S AD - School of Mechanical Engineering, Kookmin University, Seoul 02707, Korea. FAU - Kim, Sang Moon AU - Kim SM AUID- ORCID: 0000-0002-2311-2211 AD - Department of Mechanical Engineering, Incheon National University, Incheon 22012, Korea. LA - eng GR - 2019R1C1C1006392/National Research Foundation of Korea/ GR - 2020-0364/Incheon National University/ PT - Journal Article DEP - 20211213 PL - Switzerland TA - Polymers (Basel) JT - Polymers JID - 101545357 PMC - PMC8709208 OTO - NOTNLM OT - UV curable polymer OT - aperture OT - buckling OT - membranes OT - structural stability COIS- The authors declare no conflict of interest. EDAT- 2021/12/29 06:00 MHDA- 2021/12/29 06:01 PMCR- 2021/12/13 CRDT- 2021/12/28 01:08 PHST- 2021/11/05 00:00 [received] PHST- 2021/12/09 00:00 [revised] PHST- 2021/12/10 00:00 [accepted] PHST- 2021/12/28 01:08 [entrez] PHST- 2021/12/29 06:00 [pubmed] PHST- 2021/12/29 06:01 [medline] PHST- 2021/12/13 00:00 [pmc-release] AID - polym13244361 [pii] AID - polymers-13-04361 [pii] AID - 10.3390/polym13244361 [doi] PST - epublish SO - Polymers (Basel). 2021 Dec 13;13(24):4361. doi: 10.3390/polym13244361.