Polymer fiber interconnects are produced between microscale features on
substrate using only electrostatic forces. In one embodiment, electric
field driven directed growth of fibers is achieved between microscale
droplets of a concentrated polymer solution deposited on a substrate
associated with a capacitor, such as an interdigitated capacitor. After
depositing the droplets, the droplets on or near the positive electrode
become positively charged and the droplets on or near the negative
electode become negatively charged. Fibers form between the positively
and negatively charged droplets due to electrostatic forces. In a second
embodiment, positively charged and negatively droplets are created by
electrospraying or by other means, and the fibers spontaneously form
between droplets of opposite polarity. The process is similar to
conventional electrospinning, but is achieved on a micrscopic scale and
utilizes significantly lower driving potentials.