This paper presents a comprehensive exploration of Surface-Enhanced Raman Spectroscopy (SERS) substrate design, leveraging Finite-Difference Time-Domain (FDTD) simulations for systematic parameter sweeping. Our investigation goes beyond enhancing SERS performance, addressing the crucial aspect of manufacturability with two-photon polymerization (2PP). By examining parameters such as height, pitch, and diameter, we aim to identify structures that not only exhibit high enhancement factors but also possess higher tolerances suitable for practical fabrication. Novel models are developed to visualize SERS hotspots based on nominal shape and AFM data, providing valuable insights for both substrate performance and manufacturability. This dual-focused strategy, integrating FDTD modeling with 2PP fabrication, offers an understanding for advancing SERS substrate design in both sensitivity and practicality.
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