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This paper presents polycarbonate negative topographies used as substrates for the templated self- assembly of microsphere-based microrobots. This approach protects primary structures from damage during molding and de-molding, providing high fidelity negatives of arrays for assembly via templated assembly by selective removal (TASR). We show that reducing the surface energy mismatch between the microspheres and substrate results in yield increases up to 790%. This work addresses yield-related challenges of multicomponent microsystem assembly with existing PDMS-based templated assembly methods. The application of this technology in DNA microswimmer fabrication is demonstrated. 

Magnetically-actuated swimming microrobots are an emerging tool for navigating and manipulating materials in confined spaces. Recent work has demonstrated that it is possible to build such systems at the micro and nanoscales using polymer microspheres, magnetic particles and DNA nanotechnology. However, while these materials enable an unprecedented ability to build at small scales, such systems often demonstrate significant polydispersity resulting from both the material variations and the assembly process itself. This variability makes it difficult to predict, let alone optimize, the direction or magnitude of microswimmer velocity from design parameters such as link shape or aspect ratio. To isolate questions of a swimmer's design from variations in its physical dimensions, we present a novel experimental platform using two-photon polymerization to build a two-link, buoyant milliswimmer with a fully customizable shape and integrated flexible linker (the swimmer is underactuated, enabling asymmetric cyclic motion and net translation). Our approach enables us to control both swimming direction and repeatability of swimmer performance. These studies provide ground truth data revealing that neither the first order nor second order models currently capture the key features of milliswimmer performance. We therefore use our experimental platform to develop design guidelines for tuning the swimming speeds, and we identify the following three approaches for increasing speed: (1) tuning the actuation frequency for a fixed aspect ratio, (2) adjusting the aspect ratio given a desired range of operating frequencies, and (3) using the weaker value of linker stiffness from among the values that we tested, while still maintaining a robust connection between the links. We also find experimentally that spherical two-link swimmers with dissimilar link diameters achieve net velocities comparable to swimmers with cylindrical links, but that two-link spherical swimmers of equal diameter do not.