Monocrystalline Nanopatterns Made by Nanocube Assembly and Epitaxy

Silver Nanocube Epitaxy via Nanogap-Induced Electrostatics

Silver nanostructures are highly valued in nanophotonic devices due to their appealing plasmonic properties and affordability relative to gold. Yet, fabricating high-quality, monocrystalline silver nanostructures, with full control over the shape, is challenging. A mild, liquid-phase method for the epitaxial welding of adjacent monocrystalline silver nanocubes in reductant-free conditions is introduced to prevent the formation of detrimental nuclei on the surface that can degrade the nanostructures' optical qualities. The mechanism is thoroughly investigated and it is found that the nanocubes themselves can act as reducing agents, promoting growth preferentially into the gap as a result of electrostatic interactions. By controlling experimental parameters such as temperature, pH, and the introduction of capping agents, a balance between nanocube epitaxy and shape retention is achieved. Finally, by applying this procedure to nanoparticle assembled in predefined meta-atoms, the feasibility of creating intricate silver nanostructures, that are monocrystalline as verified by transmission electron microscopy (TEM), is demonstrated. This advancement paves the way for bottom-up fabrication of optical metasurfaces that can be swiftly integrated in devices.

Designer Metasurfaces via Nanocube Assembly at the Air-Water Interface

The advent of metasurfaces has revolutionized the design of optical instruments, and recent advancements in fabrication techniques are further accelerating their practical applications. However, conventional top-down fabrication of intricate nanostructures proves to be expensive and time-consuming, posing challenges for large-scale production. Here, we propose a cost-effective bottom-up approach to create nanostructure arrays with arbitrarily complex meta-atoms displaying single nanoparticle lateral resolution over submillimeter areas, minimizing the need for advanced and high-cost nanofabrication equipment. By utilizing air/water interface assembly, we transfer nanoparticles onto templated polydimethylsiloxane (PDMS) irrespective of nanopattern density, shape, or size. We demonstrate the robust assembly of nanocubes into meta-atoms with diverse configurations generally unachievable by conventional methods, including U, L, cross, S, T, gammadion, split-ring resonators, and Pancharatnam-Berry metasurfaces with designer optical functionalities. We also show nanocube epitaxy at near ambient temperature to transform the meta-atoms into complex continuous nanostructures that can be swiftly transferred from PDMS to various substrates via contact printing. Our approach potentially offers a large-scale manufacturing alternative to top-down fabrication for metal nanostructuring, unlocking possibilities in the realm of nanophotonics.

Pushing the Limits of Capillary Assembly for the Arbitrary Positioning of Sub-50nm Nanocubes in Printable Plasmonic Surfaces

The fabrication of high quality nanophotonic surfaces for integration in optoelectronic devices remains a challenge because of the complexity and cost of top-down nanofabrication strategies. Combining colloidal synthesis with templated self-assembly emerged as an appealing low-cost solution. However, it still faces several obstacles before integration in devices can become a reality. This is mostly due to the difficulty in assembling small nanoparticles (<50 nm) in complex nanopatterns with a high yield. In this study, a reliable methodology is proposed to fabricate printable nanopatterns with an aspect ratio varying from 1 to 10 and a lateral resolution of 30 nm via nanocube assembly and epitaxy. Investigating templated assembly via capillary forces, a new regime was identified that was used to assemble 30-40 nm nanocubes in a patterned polydimethylsiloxane template with a high yield for both Au and Ag with multiple particles per trap. This new method relies on the generation and control of an accumulation zone at the contact line that is thin as opposed to dense, displaying higher versatility. This is in contrast with conventional wisdom, identifying a dense accumulation zone as a requirement for high-yield assembly. In addition, different formulations are proposed that can be used for the colloidal dispersion, showing that the standard water-surfactant solutions can be replaced by surfactant-free ethanol solutions, with good assembly yield. This allows to minimize the presence of surfactants that can affect electronic properties. Finally, it is shown that the obtained nanocube arrays can be transformed into continuous monocrystalline nanopatterns via nanocube epitaxy at near ambient temperature, and transferred to different substrates via contact printing. This approach opens new doors to the templated assembly of small colloids and could find potential applications in various optoelectronic devices ranging from solar cells to light-emitting diodes and displays.

Consolidation and performance gains in plasma-sintered printed nanoelectrodes

We report on the unusual, advantageous ageing of flexible transparent electrodes (FTEs) that were self-assembled from oleylamine-capped gold nanospheres (AuNPs) by direct nanoimprinting of inks with different particle concentrations (cAu = 3 mg mL-1 to 30 mg mL-1). The resulting lines were less than 2.5 μm wide and consisted of disordered particle assemblies. Small-Angle X-ray Scattering confirmed that particle packing did not change with ink concentration. Plasma sintering converted the printed structures into lines with a thin, electrically conductive metal shell and a less conductive hybrid core. We studied the opto-electronic performance directly after plasma sintering and after fourteen days of storage at 22 °C and 55% rH in the dark. The mean optical transmittance T̄400-800 in the range from 400 nm to 800 nm increased by up to ≈ 3%, while the sheet resistance Rsh strongly decreased by up to ≈ 82% at all concentrations. We correlated the changes with morphological changes visible in scanning and transmission electron microscopy and identified two sequential ageing stages: (I) post-plasma relaxation effects in and consolidation of the shell, and (II) particle re-organization, de-mixing, coarsening, and densification of the core with plating of Au from the core onto the shell, followed by solid-state de-wetting (ink concentrations cAu < 15 mg mL-1) or stability (cAu ≥ 15 mg mL-1). The plating of Au from the hybrid core improved the FTEs' Figure of Merit FOM = T̄400-800·Rsh-1 by up to ≈ 5.8 times and explains the stable value of ≈ 3.3%·Ωsq-1 reached after 7 days of ageing at cAu = 30 mg mL-1.

Nanoparticle Imprint Lithography: From Nanoscale Metrology to Printable Metallic Grids

Large scale and low-cost nanopatterning of materials is of tremendous interest for optoelectronic devices. Nanoimprint lithography has emerged in recent years as a nanofabrication strategy that is high-throughput and has a resolution comparable to that of electron-beam lithography (EBL). It is enabled by pattern replication of an EBL master into polydimethylsiloxane (PDMS), that is then used to pattern a resist for further processing, or a sol-gel that could be calcinated into a solid material. Although the sol-gel chemistry offers a wide spectrum of material compositions, metals are still difficult to achieve. This gap could be bridged by using colloidal nanoparticles as resist, but deep understanding of the key parameters is still lacking. Here, we use supported metallic nanocubes as a model resist to gain fundamental insights into nanoparticle imprinting. We uncover the major role played by the surfactant layer trapped between nanocubes and substrate, and measure its thickness with subnanometer resolution by using gap plasmon spectroscopy as a metrology platform. This enables us to quantify the van der Waals (VDW) interactions responsible for the friction opposing the nanocube motion, and we find that these are almost in quantitative agreement with the Stokes drag acting on the nanocubes during nanoimprint, that is estimated with a simplified fluid mechanics model. These results reveal that a minimum thickness of surfactant is required, acting as a spacer layer mitigating van der Waals forces between nanocubes and the substrate. In the light of these findings we propose a general method for resist preparation to achieve optimal nanoparticle mobility and show the assembly of printable Ag and Au nanocube grids, that could enable the fabrication of low-cost transparent electrodes of high material quality upon nanocube epitaxy.

Design of infrared optical absorber using silver nanorings array made by a top-down process

This paper presents the numerical simulation and fabrication of a metasurface composed of silver nanorings with a split-ring gap. These nanostructures can exhibit optically-induced magnetic responses with unique possibilities to control absorption at optical frequencies. The absorption coefficient of the silver nanoring was optimized by performing a parametric study with Finite Difference Time Domain (FDTD) simulations. The absorption and scattering cross sections of the nanostructures are numerically calculated to assess the impact of the inner and outer radii, the thickness and the split-ring gap of one nanoring, as well as the periodicity factor for a group of four nanorings. This showed full control on resonance peaks and absorption enhancement in the near infrared spectral range. The experimental fabrication of this metasurface made of an array of silver nanorings is achieved by e-beam lithography and metallization. Optical characterizations are then carried out and compared to the numerical simulations. In contrast to usual microwave split-ring resonator metasurfaces reported in literature, the present study shows both the realization by a top-down process and modelling performed in the infrared frequency range.

Nanocube Epitaxy for the Realization of Printable Monocrystalline Nanophotonic Surfaces

Plasmonic nanoparticles of the highest quality can be obtained via colloidal synthesis at low-cost. Despite the strong potential for integration in nanophotonic devices, the geometry of colloidal plasmonic nanoparticles is mostly limited to that of platonic solids. This is in stark contrast to nanostructures obtained by top-down methods that offer unlimited capability for plasmon resonance engineering, but present poor material quality and have doubtful perspectives for scalability. Here, an approach that combines the best of the two worlds by transforming assemblies of single-crystal gold nanocube building blocks into continuous monocrystalline plasmonic nanostructures with an arbitrary shape, via epitaxy in solution at near ambient temperature, is introduced. Nanocube dimers are used as a nanoreactor model system to investigate the mechanism in operando, revealing competitive redox processes of oxidative etching at the nanocube corners and simultaneous heterogeneous nucleation at their surface, that ensure filling of the sub-nanometer gap in a self-limited manner. Applying this procedure to nanocube arrays assembled in a patterned poly(dimethylsiloxane) (PDMS) substrate, it is able to obtain printable monocrystalline nanoantenna arrays that can be swiftly integrated in devices. This may lead to the implementation of low-cost nanophotonic surfaces of the highest quality in industrial products.

Ion Exchange Lithography: Localized Ion Exchange Reactions for Spatial Patterning of Perovskite Semiconductors and Insulators

Patterning materials with different properties in a single film is a fundamental challenge and essential for the development of next-generation (opto)electronic functional components. This work introduces the concept of ion exchange lithography and demonstrates spatially controlled patterning of electrically insulating films and semiconductors with tunable optoelectronic properties. In ion exchange lithography, a reactive nanoparticle "canvas" is locally converted by printing ion exchange "inks." To demonstrate the proof of principle, a canvas of insulating nanoporous lead carbonate is spatioselectively converted into semiconducting lead halide perovskites by contact printing an ion exchange precursor ink of methylammonium and formamidinium halides. By selecting the composition of the ink, the photoluminescence wavelength of the perovskite semiconductors is tunable over the entire visible spectrum. A broad palette of conversion inks can be applied on the reactive film by printing with customizable stamp designs, spray-painting with stencils, and painting with a brush to inscribe well-defined patterns with tunable optoelectronic properties in the same canvas. Moreover, the optoelectronic properties of the converted canvas are exploited to fabricate a green light-emitting diode (LED), demonstrating the functionality potential of ion exchange lithography.

Top-Down Heterogeneous Colloidal Engineering Using Capillary Assembly of Liquid Particles

Capillary assembly of liquid particles (CALP) is a microfabrication strategy for engineering arbitrarily shaped polymer colloids. The method entails depositing emulsion particles into patterned microarrays within a fluidic cell: coalescence, polymerization, and extraction of the deposited material engender faceted colloids. Herein, the versatility of CALP is demonstrated by using both consecutive assembly and heterogeneous coassembly to engineer geometrically diverse Janus and patchy colloids. Liquid particles (LPs) can be patterned laterally across the plane of the template by manipulating the capillary immersion force, liquid particle hardness, and rate of coalescence. Bilayers of different polymeric LPs and patchy microarrays are fabricated, comprising solid colloids made from various materials including poly(styrene), p-styryltrimethoxysilane, and iron oxide. Eleven different structures including concentric Janus squares, triblock ellipsoids, and planar tetramer and pentagonal patchy particles are described. All particles are fluorescently labeled, resist flocculation, withstand extended heating, and endure dispersion in organic solvent. Further crystallization and processing into colloid-based microscale devices is therefore anticipated. Heterogeneous CALP combines top-down microfabrication with bottom-up synthesis to engineer nonequilibrium particle structures that cannot be made with wet chemistry. CALP enables the design and fabrication of colloids with complex internal construction to target hierarchical functional materials. Ultimately, the integration of colloidal building blocks comprising multiple components that are independently addressable is crucial for the development of nano/micromaterials such as filtration devices, sensors, diagnostics, solid-state catalysts, and optical electronics.

Nanocube Imprint Lithography

In recent years, imprint lithography has emerged as a promising patterning technique capable of high-speed and volume production. In this work, we report highly reproducible one-step printing of metal nanocubes. A dried film of monocrystalline silver cubes serves as the resist, and a soft polydimethylsiloxane stamp directly imprints the final pattern. The use of atomically smooth and sharp faceted nanocubes facilitates the printing of high-resolution and well-defined patterns with face-to-face alignment between adjacent cubes. It also permits digital control over the line width of patterns such as straight lines, curves, and complex junctions over an area of several square millimeters. Single-particle lattices as well as three-dimensional nanopatterns are also demonstrated with an aspect ratio up to 5 in the vertical direction. The high-fidelity nanocube patterning combined with the previously demonstrated epitaxial overgrowth can enable curved (single) crystals from solution at room temperature or highly efficient transparent conductors.

Capillary Assembly of Liquid Particles

Capillary assembly is a versatile method for depositing colloidal particles within templates, resulting in nano/microarrays and colloidal superstructures for optical, plasmonic, and sensory applications. Liquid particles (LPs), comprised of oligomerized 3-(trimethoxysilyl)propyl methacrylate, are herein shown to deposit into patterned cavities via capillary assembly. In contrast to solid colloids, LPs coalesce upon solvent evaporation and assume the geometry of the template. Incorporating small molecules such as dyes followed by LP solidification generates fluorescent polymer microarrays of any geometry. The LP size is inversely proportional to the quantity of deposited material and the convexity of the final polymer array. Cavity filling can be tuned by increasing the assembly temperature. Extraction of the polymerized regions produces solidified particles with faceted shapes including square prisms, trapezoids, and ellipsoids with sizes up to 14 µm that retain the shape of the cavity in which they are initially held. LP deposition thus presents a highly controllable fabrication scheme for geometrically diverse polymer microarrays and anisotropic colloids of any conceivable polygonal shape due to space filling of the template. The extension of capillary assembly to LPs that can be doped with small molecule dyes and analytes invaluably expands the synthetic toolbox for top-down, scalable, hierarchically engineered materials.

Quantifying Strain and Dislocation Density at Nanocube Interfaces after Assembly and Epitaxy

Nanoparticle self-assembly and epitaxy are utilized extensively to make 1D and 2D structures with complex shapes. High-resolution transmission electron microscopy (HRTEM) has shown that single-crystalline interfaces can form, but little is known about the strain and dislocations at these interfaces. Such information is critically important for applications: drastically reducing dislocation density was the key breakthrough enabling widespread implementation of light-emitting diodes, while strain engineering has been fundamental to modern high-performance transistors, solar cells, and thermoelectrics. In this work, the interfacial defect and strain formation after self-assembly and room temperature epitaxy of 7 nm Pd nanocubes capped with polyvinylpyrrolidone (PVP) is examined. It is observed that, during ligand removal, the cubes move over large distances on the substrate, leading to both spontaneous self-assembly and epitaxy to form single crystals. Subsequently, atomically resolved images are used to quantify the strain and dislocation density at the epitaxial interfaces between cubes with different lateral and angular misorientations. It is shown that dislocation- and strain-free interfaces form when the nanocubes align parallel to each other. Angular misalignment between adjacent cubes does not necessarily lead to grain boundaries but does cause dislocations, with higher densities associated with larger rotations.

Arbitrary Gold Nanoparticle Arrays Fabricated through AFM Nanoxerography and Interfacial Seeded Growth

Based on arrays of Au seeds fabricated with atomic force microscopy (AFM) nanoxerography, the seeded growth of gold nanoparticles (Au NPs) on surface is achieved. The size evolution of Au NPs in each spot is tracked by in situ AFM and SEM images because each spot can be easily localized in the array system. The extinction microspectra extracted in real time with enhanced signals and red-shift can further monitor the increasing size of Au NPs. As a powerful platform, AFM nanoxerography makes it easy to tune the spot size and the intervals among spots in the Au NP arrays without preparing a template. It also allows for fabricating arbitrary patterns including various symbols and graphs. More interestingly, the in situ growth of Au NPs offers an approach to decreasing the interparticle distance, and thus forming closely interconnected Au nanowire assembly, exhibiting immense potential in the nanoelectronic system.

Assembly and Dynamic Analysis of Square Colloidal Crystals via Templated Capillary Assembly

Capillary assembly has the ability to engineer centimeter-sized regions of discrete colloidal superstructures and microarrays. However, its use as a tool for directing crystallization of colloids into surface-bound nonclose-packed arrays is limited. Furthermore, the use of quantitative particle tracking tools to investigate evaporative assembly dynamics is rarely employed. In this contribution, we use templated capillary assembly to fabricate square-packed lattices of spherical, organosilica colloids using designed patterned boundaries. Particle tracking algorithms reveal that the assembly of square-packed regions is controlled by the interplay between confinement-driven nuclei formation and osmotic pressure-driven restructuring. We find that the incorporation of a square template increases the yield of particles bearing four nearest neighbors (Z_n = 4) from 4 to 39%, obtained using a heavier and more viscous solvent. Maximal square-packed domains occur at specific initial particle concentrations (1.75-2.25 wt % or φ = 0.013-0.017), indicating that rearrangements are a function of osmotic force. We use particle tracking methods to dynamically monitor conversions between square and hexagonal packing, revealing a cyclical transition between 4 and 6 coordinated particles throughout meniscus recession. Our method is highly scalable and inexpensive and can be adapted for use with different particle sizes and compositions, as well as for targeted open-packed geometries. Our findings will inform the large area, defect-free assembly of nonclose-packed lattices of unexplored varieties that are necessary for the continued expansion of colloid-based materials with vast applications in optical electronics.

Convectively Assembled Monolayers of Colloidal Cubes: Evidence of Optimal Packings

We employ a system of cubic colloids with rounded corners to study the close-packed monolayers that form via convective assembly. We show that by controlled solvent evaporation large densely packed monolayers of colloidal cubes are obtained. Using scanning electron microscopy and particle-tracking algorithms, we investigate the local order in detail and show that the obtained monolayers possess their predicted close-packed optimal packings, the Λ₀-lattice and the Λ₁-lattice, as well as the simple square-lattice and disordered packings. We further show that shape details of the cube corners are important for the final packing symmetry, where the frequency of the Λ₁-lattice increases with decreasing roundness of the corners, whereas the frequency of the Λ₀-lattice is unaffected. The formation of both optimal packings is found to be a consequence of the out-of-equilibrium formation process, which leads to small shifts in rows of cubes, thereby transforming the Λ₁-lattice into the Λ₀-lattice.

Arrays of highly complex noble metal nanostructures using nanoimprint lithography in combination with liquid-phase epitaxy

Current best-practice lithographic techniques are unable to meet the functional requirements needed to enable on-chip plasmonic devices capable of fully exploiting nanostructure properties reliant on a tailored nanostructure size, composition, architecture, crystallinity, and placement. As a consequence, numerous nanofabrication methods have emerged that address various weaknesses, but none have, as of yet, demonstrated a large-area processing route capable of defining organized surfaces of nanostructures with the architectural diversity and complexity that is routinely displayed in colloidal syntheses. Here, a hybrid fabrication strategy is demonstrated in which nanoimprint lithography is combined with templated dewetting and liquid-phase syntheses that is able to realize periodic arrays of complex noble metal nanostructures over square centimeter areas. The process is inexpensive, can be carried out on a benchtop, and requires modest levels of instrumentation. Demonstrated are three fabrication schemes yielding arrays of core-shell, core-void-shell, and core-void-nanoframe structures using liquid-phase syntheses involving heteroepitaxial deposition, galvanic replacement, and dealloying. With the field of nanotechnology being increasingly reliant on the engineering of desirable physicochemical responses through architectural control, the fabrication strategy provides a platform for advancing devices reliant on addressable arrays or the collective response from an ensemble of identical nanostructures.

Capillary assembly as a tool for the heterogeneous integration of micro- and nanoscale objects

During the past decade, capillary assembly in topographical templates has evolved into an efficient method for the heterogeneous integration of micro- and nano-scale objects on a variety of surfaces. This assembly route has been applied to a large spectrum of materials of micrometer to nanometer dimensions, supplied in the form of aqueous colloidal suspensions. Using systems produced via bulk synthesis affords a huge flexibility in the choice of materials, holding promise for the realization of novel superior devices in the fields of optics, electronics and health, if they can be integrated into surface structures in a fast, simple, and reliable way. In this review, the working principles of capillary assembly and its fundamental process parameters are first presented and discussed. We then examine the latest developments in template design and tool optimization to perform capillary assembly in more robust and efficient ways. This is followed by a focus on the broad range of functional materials that have been realized using capillary assembly, from single components to large-scale heterogeneous multi-component assemblies. We then review current applications of capillary assembly, especially in optics, electronics, and in biomaterials. We conclude with a short summary and an outlook for future developments.