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 project has evolved from solving everyday laboratory inconveniences to engineering critical infrastructure for automated research workflows. By leveraging additive manufacturing, I design and fabricate custom interfaces that bridge the gap between standard laboratory equipment and advanced robotic systems. Recent work focuses on high-throughput sample handling and automated characterization, enabling the integration of North Robotics arms and motorized stages into closed-loop experimental cycles. This initiative demonstrates how rapid prototyping can unlock new capabilities in materials science research.

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

• Ossila Four-Point Probe Automated Mount
  The Design: A precision bracket that mounts the Ossila probe head directly onto a Thorlabs KVS30/M motorized vertical stage.
  Impact: Transitioned the lab from manual to fully automated conductivity measurements. By using Python scripts to control the stage, the probe now contacts samples at the exact same pressure and height every time, completely eliminating human error.
• North Robotics N9 Drop Cast Holder
  The Design: A custom platform that replaces the standard "wafer garage" on the N9 system, utilizing existing alignment pins for a perfect fit.
  Impact: This "hack" repurposed a high-end robot for specific thin-film applications, allowing it to directly deposit solutions into drop-cast structures with high repeatability.
• High-Capacity Thin-Film Sample Holders
  The Design: Custom-engineered holders with optimized spatial geometry to secure thin-film samples during processing.
  Impact: Redesigned the standard architecture to fit 100 samples within the same footprint that originally held only 20. This 500% increase in capacity significantly reduced cost-per-sample and maximized throughput.
• Universal Testing Machine (UTM) Protective Cover
  The Design: A custom-fitted housing for the Universal Testing Machine's sensitive mechanics.
  Impact: Protects internal components from dust and accidental splashes during wet tensile testing, preventing corrosion and debris buildup on the drive system.
• Lab Hood Edge-Mount Pipette Holder
  The Design: A space-saving C-port clip that attaches directly to the metal lip of a fume hood.
  Impact: Cleared the deck of clutter by moving expensive tools to eye level, improving workflow organization and maintaining better airflow and sterility within the hood.
• Robosoccer Competition Attachments
  The Design: A two-part system featuring a front-end "pusher/plow" for ball control and a protective top housing.
  Impact: Turned a base-model robot into a championship winner by providing superior ball handling and protecting the electronics from high-speed collisions.

Laying the "Walking Blocks"

A true closed-loop system requires mastering individual instrument control first. By developing custom Python drivers, I have created a Hardware Abstraction Layer (HAL) that allows a central computer to coordinate disparate hardware—originally designed as standalone units—into a single, unified laboratory ecosystem.

Developed Hardware Infrastructure

Access the specific drivers developed for each laboratory "block":

The Integrated Autonomous Loop

I am currently integrating these drivers with our N9 North Robotics platform to achieve a fully automated cycle: