Sabin Baral

Project Overview

This research focuses on developing efficient methodologies for fabricating and characterizing block copolymer thin films at scale. Block copolymers self-assemble into nanoscale structures that have applications in next-generation semiconductor manufacturing, filtration membranes, and energy storage devices. The high-throughput approach allows for rapid screening of processing conditions to optimize film morphology and properties.

My Role & Responsibilities

As the lead undergraduate researcher on this project, I designed and executed the experimental workflow including:

• Sample preparation using spin-coating and thermal annealing techniques
• Conducting GIWAXS and GISAXS measurements at synchrotron facilities
• Data analysis and pattern interpretation using IgorPro and Python
• Developing automated processing scripts to handle large datasets

Techniques & Methods

• Grazing-Incidence Wide-Angle X-ray Scattering (GIWAXS) - Crystalline structure analysis
• Grazing-Incidence Small-Angle X-ray Scattering (GISAXS) - Morphology characterization
• Atomic Force Microscopy (AFM) - Surface topography imaging
• Thermal Analysis - DSC and TGA for phase behavior studies
• Computational Tools - MATLAB and Python for data processing and visualization

Results & Outcomes

Developed a streamlined workflow that reduced characterization time by 40% while maintaining data quality. Identified key processing parameters that influence domain spacing and orientation. Results contributed to understanding structure-property relationships in block copolymer systems. Currently preparing 300+ thin film samples for our next beamtime at ALS or NSLS.

Links & Resources

Lab Group Website

Project Overview

Organic photovoltaics (OPVs) offer a promising pathway to sustainable energy with advantages like flexibility, low-cost manufacturing, and tunable optical properties. This project investigated the thermal stability of polymer-based solar cells, addressing one of the key challenges limiting their commercial viability. Understanding degradation mechanisms under thermal stress is critical for extending device lifetime and improving performance reliability.

My Role & Responsibilities

I was responsible for the complete device lifecycle from fabrication to characterization:

• Fabricating organic solar cells using solution processing and vacuum deposition techniques
• Conducting accelerated aging studies under controlled temperature conditions
• Measuring current-voltage characteristics and power conversion efficiency
• Performing morphological analysis using AFM to track structural changes
• Analyzing thermal stability using TGA and DSC and X ray techniques.
• Correlating performance degradation with structural and compositional changes

Techniques & Methods

• Device Fabrication - Spin coating, thermal evaporation, and encapsulation
• J-V Characterization - Solar simulator and source meter measurements
• Atomic Force Microscopy (AFM) - Surface morphology and phase separation analysis
• Thermal Analysis - TGA for decomposition temperature, DSC for glass transition
• UV-Vis Spectroscopy - Absorption spectra and optical bandgap determination
• Data Analysis - OriginPro and Python for statistical analysis and visualization

Results & Outcomes

Identified critical temperature thresholds beyond which device performance degrades significantly. Discovered that morphological stability of the active layer is a primary factor in thermal degradation. Proposed optimized annealing protocols that improve initial efficiency while maintaining better long-term stability.

Links & Resources

Research Poster | Lab Website

Project Overview

This ongoing initiative demonstrates the practical application of additive manufacturing to solve real-world challenges in laboratory and everyday settings. By leveraging 3D printing technology, I've developed custom solutions ranging from specialized lab equipment holders to functional prototypes for research applications. The project showcases the intersection of design thinking, materials knowledge, and rapid prototyping.

My Role & Responsibilities

End-to-end ownership of the design and fabrication process:

• Identifying problems and needs in laboratory and practical settings
• Conceptualizing and designing solutions using CAD software (AutoCAD, OpenSCAD)
• Optimizing designs for printability, structural integrity, and material efficiency
• 3D printing using FDM technology with mostly PLA
• Post-processing and quality testing of printed components
• Iterating designs based on lab members feedback and performance testing

Techniques & Methods

• CAD Design - AutoCAD for complex geometries, OpenSCAD for parametric modeling
• 3D Printing - FDM (Fused Deposition Modeling) with PLA, PETG, and ABS materials
• Material Selection - Choosing appropriate polymers based on mechanical requirements
• Process Optimization - Print parameter tuning for quality and efficiency
• Iterative Design - Rapid prototyping and testing cycles

Results & Outcomes

Successfully designed and fabricated over 20 unique solutions including custom sample holders for characterization equipment, modular storage systems for laboratory consumables, and specialized fixtures for experimental setups. These tools have improved lab efficiency and reduced equipment costs. The project has also enhanced my skills in design thinking, materials selection, and practical engineering problem-solving.

Example Applications

• Engineered and fabricated thin-film sample holders of varying dimensions, optimizing both cost and spatial efficiency — replacing conventional holders that fit only 20 samples, my design accommodates up to 100 samples in the same space, achieving a 500% increase in capacity.
• Developed custom vial holders tailored to different sizes and specific functional requirements.
• Designed and produced pipette holders for both fume hood applications and general laboratory use, enhancing organization and accessibility.
• Modeled and designed protective load cell covers and mounts to ensure durability and precision in experimental setups.
• Conceptualized and designed a soccer robot optimized for superior ball handling and defensive performance, giving our team a competitive edge.