Patent ID: 8703032

Claim:
A method of manufacturing a dry adhesive structure comprising overhanging cap and undercut fiber structures, the method comprising: applying a photoresistive material to a photosensitive mold substrate comprising polymethyl methacrylate; patterning and developing the photoresistive material to form a mask comprising overhanging cap structures corresponding to the dry adhesive structure, wherein the mask is substantially opaque to UV light; exposing the mask and mold substrate to UV light to pattern the mold substrate; developing the mold substrate with the substrate developer to remove an exposed portion of the mold substrate to form undercut fiber structures substantially aligned with and supporting the overhanging cap structures corresponding to the dry adhesive structure; molding an elastomer rubber material in the mold substrate to form an elastomer rubber negative mold comprising the overhanging cap and undercut fiber structures; and molding a flexible polymer material in the elastomer rubber negative mold to form the dry adhesive structure comprising the overhanging cap and undercut fiber structures.