Adhesion induced mesoscale instability patterns in thin PDMS-metal bilayers

We show that the surface of a thin elastomer-metal (aluminum) hybrid bilayer becomes spontaneously patterned when brought in adhesive contact with a rigid surface. The self-organized surface patterns show three distinct morphological phases-columns, labyrinths, and holes-depending on the area of contact. The characteristic wavelength of these patterns is found to be 2.94 +/- 0.20 times the total film thickness, independent of the morphological phase and the surface properties of the contacting surface. Interestingly, the metal films 60-120 nm thick showed the same scaling, but the bilayers with thicker metal films were completely stable. This observation demonstrates for the first time a hard transition to the instability as the elastic stiffness of the film is varied. We also report a protocol for alignment of the instability patterns and for transferring the metal patterns to another surface. (C) 2008 American Institute of Physics.