Vapor sublimation and deposition to build porous particles and composites

Vapor Deposition of Polymer Structures: From 2D Surface Coatings and Surface Microstructures to 3D Building Blocks and Structural Monoliths

Vapor deposition of polymers offers precise control over polymerization, enabling the creation of uniform thin films, conformal coatings, and complex geometries. These methods produce pinhole-free films with tailored physical and chemical properties while addressing the limitations of conventional solution-based techniques. Recent advancements have extended polymer fabrication beyond thin films to include surface patterns, microstructures, and 3D architectures. This review provides an overview of vapor deposition methods, polymerization mechanisms, and processes for fabricating microstructures and 3D architectures. This review highlights the progress of vapor-deposited polymers, from simple coatings to complex, multifunctional structures. By integrating precise structural control with chemical versatility, these advancements open new opportunities for innovative material design and address the growing demands of modern applications.

Controlling Superhydrophobicity on Complex Substrates Based on a Vapor-Phase Sublimation and Deposition Polymerization

The superhydrophobic properties of material surfaces have attracted significant research and practical development in a wide range of applications. In the present study, a superhydrophobic coating was fabricated using a vapor-phase sublimation and deposition process. This process offers several advantages, including a controllable and tunable superhydrophobic property, a dry and solvent-free process that uses well-defined water/ice templates during fabrication, and a coating technology that is applicable to various substrates, regardless of their dimensions or complex geometric configurations. The fabrication process exploits time-dependent condensation to produce ice templates with a controlled surface morphology and roughness. The templates are sacrificed via vapor sublimation, which results in mass transfer of water vapor out of the system. A second vapor source of a polymer precursor is then introduced to the system, and deposition occurs upon polymerization on the iced templates, replicating the same topologies from the iced templates. The continuation of the co-current sublimation and deposition processes finally renders permanent hierarchical structures of the polymer coatings that combine the native hydrophobic property of the polymer and the structured property by the sacrificed ice templates, achieving a level of superhydrophobicity that is tunable from 90° to 164°. The experiments demonstrated the use of [2,2]paracyclophanes as the starting materials for forming the superhydrophobic coatings of poly(p-xylylenes) on substrate surfaces. In comparison to conventional vapor deposition of poly(p-xylylenes), which resulted in dense thin-film coatings with only a moderate water contact angle of approximately 90°, the reported superhydrophobic coatings and fabrication process can achieve a high water contact angle of 164°. Demonstrations furthermore revealed that the proposed coatings are durable while maintaining superhydrophobicity on various substrates, including an intraocular lens and a cardiovascular stent, even against harsh treatment conditions and varied solution compositions used on the substrates.

Ice-templated synthesis of multicomponent porous coatings via vapour sublimation and deposition polymerization

A multicomponent vapour-deposited porous (MVP) coating with combined physical and biochemical properties was fabricated based on a chemical vapour sublimation and deposition process. Multiple components are used based on their natural thermodynamic properties, being volatile and/or nonvolatile, resulting in the sublimation of water vapour (from an iced template), and a simultaneous deposition process of poly-p-xylylene occurs upon radical polymerization into a disordered structure, forming porous coatings of MVP on various substrates. In terms of physical properties, the coating technology exhibits adjustable hydrophobicity by tuning the surface morphology by timed control of the sublimation of the iced template layer from a substrate. However, by using a nonvolatile solution during fabrication, an impregnation process of the deposited poly-p-xylylene on such a solution with tuning contact angles produces an MVP coating with a customizable elastic modulus based on deformation-elasticity theory. Moreover, patterning physical structures with adjustable pore size and/or porosity of the coatings, as well as modulation and compartmentalization to introduce necessary boundaries of microstructures within one MVP coating layer, can be achieved during the proposed fabrication process. Finally, with a combination of defined solutions comprised of both volatile and nonvolatile multicomponents, including functional biomolecules, growth factor proteins, and living cells, the fabrication of the resultant MVP coating serves devised purposes exhibiting a variety of biological functions demonstrated with versatility for cell proliferation, osteogenesis, adipogenesis, odontogenesis, spheroid growth of stem cells, and a complex coculture system towards angiogenesis. Multicomponent porous coating technology is produced based on vapour sublimation and deposition upon radical polymerization that overturns conventional vapour-deposited coatings, resulting in only dense thin films, and in addition, the versatility of adjusting coating physical and chemical properties by exploiting the volatility mechanism of iced solution templates and accommodation of solute substances during the fabrication process. The MVP coating and the proposed fabrication technique represent a simple approach to provide a prospective interface coating layer for materials science and are attractive for unlimited applications.

Design Strategies for Structurally Controlled Polymer Surfaces via Cyclophane-Based CVD Polymerization and Post-CVD Fabrication

Molecular structuring of soft matter with precise arrangements over multiple hierarchical levels, especially on polymer surfaces, and enabling their post-synthetic modulation has tremendous potential for application in molecular engineering and interfacial science. Here, recent research and developments in design strategies for structurally controlled polymer surfaces via cyclophane-based chemical vapor deposition (CVD) polymerization with precise control over chemical functionalities and post-CVD fabrication via orthogonal surface functionalization that facilitates the formation of designable biointerfaces are summarized. Particular discussion about innovative approaches for the templated synthesis of shape-controlled CVD polymers, ranging from 1D to 3D architecture, including inside confined nanochannels, nanofibers/nanowires synthesis into an anisotropic media such as liquid crystals, and CVD polymer nanohelices via hierarchical chirality transfer across multiple length scales is provided. Aiming at multifunctional polymer surfaces via CVD copolymerization of multiple precursors, the structural and functional design of the fundamental [2.2]paracyclophane (PCP) precursor molecules, that is, functional CVD monomer chemistry is also described. Technologically advanced and innovative surface deposition techniques toward topological micro- and nanostructuring, including microcontact printing, photopatterning, photomask, and lithographic techniques such as dip-pen nanolithography, showcasing research from the authors' laboratories as well as other's relevant important findings in this evolving field are highlighted that have introduced new programmable CVD polymerization capabilities. Perspectives, current limitations, and future considerations are provided.

Hybrid Surface Nanostructures Using Chemical Vapor Deposition and Colloidal Self-Assembled Patterns for Human Mesenchymal Stem Cell Culture—A Preliminary Study

Surface coatings are critical in biomaterials and biomedical devices. Chemical vapor deposition (CVD) is a well-known technology for the generation of thin films on a surface. However, the granular structures produced using CVD are rare. Recently, we used PPX-C, an excellent insulating material, for granular structure coating using CVD. Colloidal self-assembly is also a well-established method to generate granular structures named colloidal self-assembled patterns (cSAPs). In this study, we combined these two technologies to generate hierarchical granular structures and tested the biophysical effect of these hybrid surfaces on human bone marrow mesenchymal stem cells (hBMSCs). Two CVD-derived granular structures were made using water or glycerin droplets (i.e., CVD or GlyCVD surfaces). Water drops generate porous particles, while glycerin drops generate core–shell particles on the surface. These particles were dispersed randomly on the surface with sizes ranging from 1 to 20 μm. These CVD surfaces were hydrophobic (WCA ~ 80–110 degrees). On the other hand, a binary colloidal crystal (BCC), one type of cSAPs, composed of 5 μm Si and 400 nm carboxylated polystyrene (PSC) particles, had a close-packed structure and a hydrophilic surface (WCA ~ 45 degrees). The hybrid surfaces (i.e., CVD-BCC and GlyCVD-BCC) were smooth (Ra ~ 1.1–1.5 μm) and hydrophilic (WCA ~ 50 degrees), indicating a large surface coverage of BCC dominating the surface property. The hybrid surfaces were expected to be slightly negatively charged due to naturally charged CVD particles and negatively charged BCC particles. Cell adhesion was reduced on the hybrid surfaces, leading to an aggregated cell morphology, without reducing cell activity, compared to the flat control after 5 days. qPCR analysis showed that gene expression of type II collagen (COL2) was highly expressed on the GlyCVD-BCC without chemical induction after 3 and 14 days compared to the flat control. This proof-of-concept study demonstrates the potential of combining two technologies to make hybrid structures that can modulate stem cell attachment and differentiation.

Vapor construction and modification of stem cell-laden multicomponent scaffolds for regenerative therapeutics

Tissue engineering based on the combined use of isolated cells, scaffolds, and growth factors is widely used; however, the manufacture of cell-preloaded scaffolds faces challenges. Herein, we fabricated a multicomponent scaffold with multiple component accommodations, including bioactive molecules (BMs), such as fibroblast growth factor-2 (FGF-2) and l-ascorbic acid 2-phosphate (A2-P), and living cells of human adipose-derived stem cells (hASCs), within one scaffold construct. We report an innovative fabrication process based on vapor-phased construction using iced templates for vapor sublimation. Simultaneously, the vaporized water molecules were replaced by vapor deposition of poly-p-xylylene (PPX, USP Class VI, highly compatible polymer, FDA-approved records), forming a three-dimensional and porous scaffold matrix. More importantly, a multicomponent modification was achieved based on using nonvolatile solutes, including bioactive molecules of FGF-2 and A2-P, and living cells of hASCs, to prepare iced templates for sublimation. Additionally, the fabrication and construction resulted in a multicomponent scaffold product comprising the devised molecules, cells, and vapor-polymerized poly-p-xylylene as the scaffold matrix. The clean and dry fabrication process did not require catalysts, initiators or plasticizers, and potentially harmful solvents, and the scaffold products were produced in simple steps within hours of the processing time. Cell viability analysis showed a high survival rate (approximately 86.4%) for the accommodated hASCs in the fabricated scaffold product, and a surprising multilineage differentiation potential of hASCs was highly upregulated because of synergistic guidance by the same accommodated FGF-2 and A2-P components. Proliferation and self-renewal activities were also demonstrated with enhancement of the multicomponent scaffold product. Finally, in vivo calvarial defect studies further revealed that the constructed scaffolds provided blood vessels to grow into the bone defect areas with enhancement, and the induced conduction of osteoblast growth also promoted bone healing toward osseointegration. The reported scaffold construction technology represents a prospective tissue engineering scaffold product to enable accommodable and customizable versatility to control the distribution and composition of loading delicate BMs and living hASCs in one scaffold construct and demonstrates unlimited applications in tissue engineering repair and regenerative medicine applications.

Vapor-phased fabrication and modulation of cell-laden scaffolding materials

Bottom-up approaches using building blocks of modules to fabricate scaffolds for tissue engineering applications have enabled the fabrication of structurally complex and multifunctional materials allowing for physical and chemical flexibility to better mimic the native extracellular matrix. Here we report a vapor-phased fabrication process for constructing three-dimensional modulated scaffold materials via simple steps based on controlling mass transport of vapor sublimation and deposition. We demonstrate the fabrication of scaffolds comprised of multiple biomolecules and living cells with built-in boundaries separating the distinct compartments containing defined biological configurations and functions. We show that the fabricated scaffolds have mass production potential. We demonstrate overall >80% cell viability of encapsulated cells and that modulated scaffolds exhibit enhanced cell proliferation, osteogenesis, and neurogenesis, which can be assembled into various geometric configurations. We perform cell co-culture experiments to show independent osteogenesis and angiogenesis activities from separate compartments in one scaffold construct.

Hybrid Nanostructures Obtained by Transport and Condensation of Tungsten Oxide Vapours onto CNW Templates

We present hybrid nanomaterial architectures, consisting of carbon nanowalls (CNW) templates decorated with tungsten oxide nanoparticles, synthesized using a mechanism based on tungsten oxide sublimation, vapor transport, followed by vapor condensation, in the absence or presence of plasma. The key steps in the decoration mechanism are the sublimation of tungsten oxides, when are exposed in vacuum at high temperature (800 °C), and their redeposition on colder surfaces (400-600 °C). The morphology and chemical composition of the hybrid architectures, as obtained from Scanning Electron Microscopy and X-ray Photoelectron Spectroscopy, are discussed with respect to substrate nature and the physical conditions of synthesis. We pointed out that the decoration process is strongly dependent on the temperature of the CNW templates and plasma presence. Thus, the decoration process performed with plasma was effective for a wider range of template temperatures, in contrast with the decoration process performed without plasma. The results are useful for applications using the sensing and photochemical properties of tungsten oxides, and have also relevance for fusion technology, tungsten walls erosion and material redeposition being widely observed in fusion machines.

Vapor Sublimation and Deposition to Fabricate a Porous Methyl Propiolate-Functionalized Poly-p-xylylene Material for Copper-Free Click Chemistry

Conventional porous materials are mostly synthesized in solution-based methods involving solvents and initiators, and the functionalization of these porous materials usually requires additional and complex steps. In the current study, a methyl propiolate-functionalized porous poly-p-xylylene material was fabricated based on a unique vapor sublimation and deposition process. The process used a water solution and ice as the template with a customizable shape and dimensions, and the conventional chemical vapor deposition (CVD) polymerization of poly-p-xylylene on such an ice template formed a three-dimensional, porous poly-p-xylylene material with interconnected porous structures. More importantly, the functionality of methyl propiolate was well preserved by using methyl propiolate-substituted [2,2]-paracyclophane during the vapor deposition polymerization process and was installed in one step on the final porous poly-p-xylylene products. This functionality exhibited an intact structure and reactivity during the proposed vapor sublimation and deposition process and was proven to have no decomposition or side products after further characterization and conjugation experiments. The electron-withdrawing methyl propiolate group readily provided efficient alkynes as click azide-terminated molecules under copper-free and mild conditions at room temperature and in environmentally friendly solvents, such as water. The resulting methyl propiolate-functionalized porous poly-p-xylylene exhibited interface properties with clickable specific covalent attachment toward azide-terminated target molecules, which are widely available for drugs and biomolecules. The fabricated functional porous materials represent an advanced material featuring porous structures, a straightforward synthetic approach, and precise and controlled interface click chemistry, rendering long-term stability and efficacy to conjugate target functionalities that are expected to attract a variety of new applications.

A Trimetallic Cobalt/Iron/Nickel Phytate Catalyst for Overall Water Splitting: Fabrication by Magnetic-Field-Assisted Bipolar Electrodeposition

Electrodeposition is an effective method to prepare various materials. We have established a bipolar electrodeposition system assisted by a constant magnetic field to fabricate a Co/Fe/Ni phytate catalyst with good electrocatalytic activity for overall water splitting. The effects of magnetic and electric fields on the catalytic properties of the material were studied. The catalyst prepared with an N-pole magnetic field (NPMF) exhibited good overall water splitting performance. Benefiting from the synergistic effect of the Co/Fe/Ni-phytate and the advantages of the N-pole magnetic field the NPMF electrode has a continuous 25 hours high-efficiency hydrogen evolution and oxygen evolution reaction at a current density of 100 mA cm^-2 in1.0 M KOH compared with commercial RuO₂ and Pt/C. Bipolar electrodeposition with a constant magnetic field is thus an efficient means to fabricate electrocatalytic water splitting catalysts.

Synergistic and Regulatable Bioremediation Capsules Fabrication Based on Vapor-Phased Encapsulation of Bacillus Bacteria and its Regulator by Poly-p-Xylylene

A regulatable bioremediation capsule material was synthesized with isolated single-strain bacteria (Bacillus species, B. CMC1) and a regulator molecule (carboxymethyl cellulose, CMC) by a vapor-phased encapsulation method with simple steps of water sublimation and poly-p-xylylene deposition in chemical vapor deposition (CVD) process. Mechanically, the capsule construct exhibited a controllable shape and dimensions, and was composed of highly biocompatible poly-p-xylylene as the matrix with homogeneously distributed bacteria and CMC molecules. Versatility of the encapsulation of the molecules at the desired concentrations was achieved in the vapor-phased sublimation and deposition fabrication process. The discovery of the fabricated capsule revealed that viable living B. CMC1 inhabited the capsule, and the capsule enhanced bacterial growth due to the materials and process used. Biologically, the encapsulated B. CMC1 demonstrated viable and functional enzyme activity for cellulase activation, and such activity was regulatable and proportional to the concentration of the decorated CMC molecules in the same capsule construct. Impressively, 13% of cellulase activity increase was realized by encapsulation of B. CMC1 by poly-p-xylylene, and a further 34% of cellulase activity increase was achieved by encapsulation of additional 2.5% CMC. Accordingly, this synergistic effectiveness of the capsule constructs was established by combining enzymatic B. CMC1 bacteria and its regulatory CMC by poly-p-xylylene encapsulation process. This reported encapsulation process exhibited other advantages, including the use of simple steps and a dry and clean process free of harmful chemicals; most importantly, the process is scalable for mass production. The present study represents a novel method to fabricate bacteria-encapsulated capsule for cellulose degradation in bioremediation that can be used in various applications, such as wastewater treatment and transforming of cellulose into glucose for biofuel production. Moreover, the concept of this vapor-phased encapsulation technology can be correspondingly used to encapsulate multiple bacteria and regulators to enhance the specific enzyme functions for degradation of various organic matters.

Vapor-Stripping and Encapsulating to Construct Particles with Time-Controlled Asymmetry and Anisotropy

An innovative chemical vapor sublimation and deposition (CVSD) process was shown to produce nanoscale anisotropic hybrid materials. Taking advantage of controlled thermodynamic properties and the mass transfer of molecules, this process allowed for water vapor sublimation from an iced template/substrate and stagewise vapor deposition of poly-p-xylylene onto the sublimating ice substrate. In this study, the use of sensitive soybean agglutinin (SBA) protein tubes was demonstrated as an example to prepare the anisotropic hybrid material based on the CVSD process. The rationale of a timing parameter, Δt, was controlled to program the sublimation of the SBA-ice templates and the deposition of poly-p-xylylene during the CVSD process. As a result of this control, a stripping stage occurred, during which SBA tubes were exposed on the particle surface, and a subsequent encapsulation stage enabled the transformation of the ice templates into a nanometer-sized anisotropic hybrid material of poly-p-xylylene as the matrix with encapsulated SBA tubes. The timing parameter Δt and the controlled stripping and encapsulating stages during CVSD represent a straightforward and intriguing mechanism stemming from physical chemistry fundamentals for the fabrication of hybrid materials from sensitive molecules and with predetermined sizes and asymmetrical shapes. A simulation analysis showed consistency with the experimental results and controllability of the timing mechanism with predictable particle sizes.

Parylene-Based Porous Scaffold with Functionalized Encapsulation of Platelet-Rich Plasma and Living Stem Cells for Tissue Engineering Applications

A scaffold was fabricated to synergistically encapsulate living human adipose-derived stem cells (hASCs) and platelet-rich plasma (PRP) based on a vapor-phase sublimation and deposition process. During the process, ice templates were prepared using sterile water as the solvent and were used to accommodate the sensitive living cells and PRP molecules. Under controlled processing conditions, the ice templates underwent vapor sublimation to evaporate water molecules, while at the same time, vapor-phase deposition of poly-p-xylylene (Parylene, USP Class VI highly biocompatible) occurred to replace the templates, and the final construction yielded a scaffold with Parylene as the matrix, with simultaneously encapsulated living hASCs and PRP molecules. Evaluation of the fabricated synergistic scaffold for the proliferation activities toward the encapsulated hASCs indicated significant augmentation of cell proliferation contributed by the PRP ingredients. In addition, osteogenic activity in the early stage by alkaline phosphatase expression and later stage with calcium mineralization indicated significant enhancement toward osteogenetic differentiation of the encapsulated hASCs, which were guided by the PRP molecules. By contrast, examinations of adipogenic activity by lipid droplet formation revealed an inhibition of adipogenesis with decreased intracellular lipid accumulation, and a statistically significant downregulation of adipogenic differentiation was postulated for the scaffold products when compared to the osteogenetic results and the control experiments. The reported fabrication method featured a clean and simple process to construct scaffolds that combined delicate living hASCs and PRP molecules inside the structure. The resultant synergistic scaffold and the selected commercially available hASCs and PRP are emerging as tissue engineering tools that provide multifunctionality for tissue repair and regeneration.

A Universal Solution of Controlling the Distribution of Multimaterials during Macroscopic Manipulation via a Microtopography-Guided Substrate

Any object can be considered as a spatial distribution of atoms and molecules; in this sense, we can manufacture any object as long as the precise distribution of atoms and molecules is achieved. However, the current point-by-point methods to precisely manipulate single atoms and single molecules, such as the scanning tunneling microscope (STM), have difficulty in manipulating a large quantity of materials within an acceptable time. The macroscopic manipulation techniques, such as magnetron sputtering, molecular beam epitaxy, and evaporation, could not precisely control the distribution of materials. Herein, we take a step back and present a universal method of controlling the distribution of multimaterails during macroscopic manipulation via microtopography-guided substrates. For any given target distribution of multimaterials in a plane, the complicated lateral distribution of multimaterials was firstly transformed into a simple spatial lamellar body. Then, a deposition mathematical model was first established based on a mathematical transformation. Meanwhile, the microtopographic substrate can be fabricated according to target distribution based on the deposition mathematical model. Following this, the deposition was implemented on the substrate according to the designed sequence and thickness of each material, resulting in the formation of the deposition body on the substrate. Finally, the actual distribution was obtained on a certain section in the deposition body by removing the upside materials. The actual distribution can mimic the target one with a controllable accuracy. Furthermore, two experiments were performed to validate our method. As a result, we provide a feasible and scalable solution for controlling the distribution of multimaterials, and point out the direction of improving the position accuracy of each material. We may achieve real molecular manufacturing and nano-manufacturing if the position accuracy of distribution approaches the atomic level.