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A microfluidic method for sensor fabrication on curved surfaces

We present a microfluidic technique for precision patterning thin-film metals (silver and gold) without the need for photolithography. This technique is employed for the fabrication of metal resistors that are subsequently utilized as temperature sensors, strain gauges, and fluid flow sensors. Patterns of thin film metal are fabricated by premixing and flowing electroless silver or gold plating solutions through predefined polydimethylsiloxane (PDMS) microchannels sealed against the surface of interest. The properties exhibited by PDMS, such as its tendency to adhere to clean surfaces and its flexibility, allow this technique to be carried out on both planar and curved surfaces.