Tuning the Porosity of Supraparticles

Hydrogel-Assisted Robust Supraparticles Evolved from Droplet Evaporation

Supraparticles, formed through the self-assembly of nanoparticles, are promising contenders in catalysis, sensing, and drug delivery due to their exceptional specific surface area and porosity. However, their mechanical resilience, especially in dimensions spanning micrometers and beyond, is challenged by the inherently weak interactions among their constituent building blocks, significantly constraining their broad applicability. Here, we have exploited a robust supraparticle fabrication strategy by integrating hydrogel components into the assembly system and evaporating on the superamphiphobic surface. The resultant SiO2/SA (sodium alginate) supraparticles, achieved by evaporating a 15% volume fraction dispersion of SiO2 nanoparticles containing 18.46 mg/mL of sodium alginate and subsequently cross-linking with Ca2+, demonstrate mechanical robustness with a fracture force of 6.04 N, representing a mechanical strength enhancement of 60 times higher than that prior to the incorporation of the hydrogel component. The supraparticles maintain their original morphology after 30 min of ultrasonic treatment (200 W), demonstrating mechanical stability. This method exhibits generalizability, enabling the customization of supraparticles with various building blocks and hydrogel backbone materials. Based on such a methodology, we have synthesized enzyme-carrying supraparticles, further expanding the potential applications in intricate cascade reactions. The encapsulated glucose oxidase and horseradish peroxidase maintained their inherent reactivity, and such hydrogel-assisted robust supraparticles exhibited exceptional performance in accurate glucose assays, indicating great practical application in biocatalysis.

Droplet evaporation on super liquid-repellent surfaces: A controllable approach for supraparticle fabrication

Supraparticles are agglomerates of nano- and/or microparticles with sizes ranging from tens to hundreds of microns, making them more accessible for handling and recovery than the building blocks. Supraparticles not only inherit the properties and functions of primary particles but also exhibit characteristics such as high porosity, large specific surface area, and improved functionalities, which can be attributed to the synergism, coupling, and co-localization among the constituents. Therefore, supraparticles hold promising applications in catalysis, drug delivery, sensing, etc. Among the various synthesizing strategies, evaporating droplets on a liquid-repellent surface is proposed as an effective approach to fabricate supraparticles with unique structural features and functions. The boundary conditions of such droplet-confinement methods significantly drive the formation of supraparticles by reducing or avoiding the use of solvents or processing liquids, which further accelerates the development and utilization of supraparticles. This paper presents an overview of recent developments in the fabrication of supraparticles by evaporating droplets on liquid-repellent surfaces. The review focuses on the evaporation processes on lubricant and superhydrophobic surfaces, structural regulation, and applications of supraparticles. Finally, an outlook on the future directions of evaporation on liquid-repellent surfaces mediated supraparticle fabrication is presented.

Surface-Templated Polymer Microparticle Synthesis Based on Droplet Microarrays

Polymer microparticle synthesis based on the surface-templated method is a simple and environmentally friendly method to produce various microparticles. Unique particles with different compositions can be fabricated by simply annealing a polymer on a liquid-repellent surface. However, there are hurdles to producing particles of homogeneous sizes with large quantities and varying the shape of particles. Here, a new approach to synthesizing multiple polymer microparticles using micropatterns with wettability contrast is presented. Polymer microparticles are formed in two steps. First, a layer of poly(sodium-4-styrenesulfonate) is deposited on the hydrophilic regions by dipping and withdrawing this micropattern from a polymer solution, and an array of microdroplets is formed. A dewetting-inducing layer on the pattern is introduced, and then target polymer patches are sequentially generated on it. By annealing over Tg, the contact line of the target polymer patch is freely receded, creating a particle form. The size and shape of the microparticle can be controlled by varying the micropatterns. In addition, it is demonstrated that microparticles made of polymer blends or polymer/nanoparticle composite are easily produced. This versatile method offers the potential of surface-templated synthesis to tailor polymer microparticles with different sizes, shapes, and functionalities in various research and applications.

Controlled Nanopore Sizes in Supraparticle Supports for Enhanced Propane Dehydrogenation with GaPt SCALMS Catalysts

The efficient immobilization of GaPt liquid metal alloy droplets onto tailored supports improves catalytic performance by preventing coalescence and subsequent loss of active surface area. Herein, we use tailored supraparticle (SP) supports with controlled nanopores to systematically study the influence of pore sizes on the catalytic stability of GaPt supported catalytically active liquid metal solution (SCALMS) in propane dehydrogenation (PDH). Initially, GaPt droplets were prepared via an atom-efficient and scalable ultrasonication method with recycling loops to yield droplets <300 nm. Subsequently, these droplets were immobilized onto SiO2-based SPs with controlled pore sizes ranging from 45 to 320 nm. Catalytic evaluations in PDH revealed that GaPt immobilized on SPs with larger pores demonstrated superior stability over 15 h time-on-stream evidenced by reduced deactivation rates from 0.046 to 0.026 h-1. Nanocomputed tomography and identical location SEM confirmed the successful immobilization of GaPt droplets within the interstitial sites formed by the primary particles constituting the SPs. These remained unchanged before and after the catalytic reaction, demonstrating efficient coalescence prevention. Our findings underscore the importance of support pore size engineering for improving the stability of GaPt SCALMS catalysts and highlight, particularly, the high potential of using SPs in this context.

Fabrication of Spherical Colloidal Supraparticles via Membrane Emulsification

Colloidal supraparticles are micrometer-scale assemblies of primary particles. These supraparticles have potential application in photonic materials, catalysis, gas adsorption, and drug delivery. Thus, the synthesis of colloidal supraparticles with a narrow size distribution and high yield has become essential. Here, we demonstrate membrane emulsification as a high-throughput approach for fabricating spherical supraparticles with a narrow size distribution and control over particle size and crystallinity. Spherical supraparticles with well-ordered surface structures are synthesized by generating emulsion droplets of an aqueous colloidal dispersion in fluorocarbon oil using a Shirasu porous glass membrane followed by the consolidation of particles through water removal within the emulsion. We systematically investigate process parameters, including the flow rate of the particle dispersion, the particle concentration, and the average pore diameter of the membrane, on the mean size and size distribution of the supraparticles, revealing key factors governing supraparticle properties and production throughput. A comparative evaluation with commonly employed methods highlights the advantage of membrane emulsification, which combines well-defined internal structure and controlled supraparticle sizes with comparably high yields on the order of tens of grams per day. Importantly, in contrast to widely used droplet-based microfluidics, membrane emulsification allows fabrication of supraparticles in nonfluorinated oil. Overall, membrane emulsification offers a simple yet versatile method for fabricating colloidal supraparticles with high quality and yield and may serve as a bridge between existing high-precision techniques, such as droplet-based microfluidics, and high-throughput processes with less control, such as spray-drying.

Functional supraparticles produced by the evaporation of binary colloidal suspensions on superhydrophobic surfaces

Hierarchically structured supraparticles can be produced by drying droplets of colloidal suspensions. Using binary suspensions provides degrees of structural and functional control beyond those possible for single components, while remaining tractable for fundamental mechanistic studies. Here, we implement evaporative co-assembly of two distinct particle types - 'large' polystyrene microparticles and 'small' inorganic oxide nanoparticles (silica, titania, zirconia, or ceria) - dried on superhydrophobic surfaces to produce bowl-shaped supraparticles. We extend this method to raspberry colloid templating, in which the binary suspension consists of titania nanoparticles together with gold-decorated polystyrene colloids. Following removal of the polymer particles, we demonstrate catalytic oxidative coupling of methanol to methyl formate using the resulting mesoporous supraparticles, showcasing their practical application.

Catalyst Supraparticles: Tuning the Structure of Spray-Dried Pt/SiO2 Supraparticles via Salt-Based Colloidal Manipulation to Control their Catalytic Performance

The structure of supraparticles (SPs) is a key parameter for achieving advanced functionalities arising from the combination of different nanoparticle (NP) types in one hierarchical entity. However, whenever a droplet-assisted forced assembly approach is used, e.g., spray-drying, the achievable structure is limited by the inherent drying phenomena of the method. In particular, mixed NP dispersions of differently sized colloids are heavily affected by segregation during the assembly. Herein, the influence of the colloidal arrangement of Pt and SiO2 NPs within a single supraparticulate entity is investigated. A salt-based electrostatic manipulation approach of the utilized NPs is proposed to customize the structure of spray-dried Pt/SiO2 SPs. By this, size-dependent separation phenomena of NPs during solvent evaporation, that limit the catalytic performance in the reduction of 4-nitrophenol, are overcome by achieving even Pt NP distribution. Additionally, the textural properties (pore size and distribution) of the SiO2 pore framework are altered to improve the mass transfer within the material leading to increased catalytic activity. The suggested strategy demonstrates a powerful, material-independent, and universally applicable approach to deliberately customize the structure and functionality of multi-component SP systems. This opens up new ways of colloidal material combinations and structural designs in droplet-assisted forced assembly approaches like spray-drying.

Emergent Properties from Three-Dimensional Assemblies of (Nano)particles in Confined Spaces

The assembly of (nano)particles into compact hierarchical structures yields emergent properties not found in the individual constituents. The formation of these structures relies on a profound knowledge of the nanoscale interactions between (nano)particles, which are often designed by researchers aided by computational studies. These interactions have an effect when the (nano)particles are brought into close proximity, yet relying only on diffusion to reach these closer distances may be inefficient. Recently, physical confinement has emerged as an efficient methodology to increase the volume fraction of (nano)particles, rapidly accelerating the time scale of assembly. Specifically, the high surface area of droplets of one immiscible fluid into another facilitates the controlled removal of the dispersed phase, resulting in spherical, often ordered, (nano)particle assemblies. In this review, we discuss the design strategies, computational approaches, and assembly methods for (nano)particles in confined spaces and the emergent properties therein, such as trigger-directed assembly, lasing behavior, and structural photonic color. Finally, we provide a brief outlook on the current challenges, both experimental and computational, and farther afield application possibilities.

Nanocrystal Assemblies: Current Advances and Open Problems

We explore the potential of nanocrystals (a term used equivalently to nanoparticles) as building blocks for nanomaterials, and the current advances and open challenges for fundamental science developments and applications. Nanocrystal assemblies are inherently multiscale, and the generation of revolutionary material properties requires a precise understanding of the relationship between structure and function, the former being determined by classical effects and the latter often by quantum effects. With an emphasis on theory and computation, we discuss challenges that hamper current assembly strategies and to what extent nanocrystal assemblies represent thermodynamic equilibrium or kinetically trapped metastable states. We also examine dynamic effects and optimization of assembly protocols. Finally, we discuss promising material functions and examples of their realization with nanocrystal assemblies.

Space-resolved dynamic light scattering within a millimeter-sized drop: From Brownian diffusion to the swelling of hydrogel beads

We present a dynamic light scattering setup to probe, with time and space resolution, the microscopic dynamics of soft matter systems confined within millimeter-sized spherical drops. By using an ad hoc optical layout, we tackle the challenges raised by refraction effects due to the unconventional shape of the samples. We first validate the setup by investigating the dynamics of a suspension of Brownian particles. The dynamics measured at different positions in the drop, and hence different scattering angles, are found to be in excellent agreement with those obtained for the same sample in a conventional light scattering setup. We then demonstrate the setup capabilities by investigating a bead made of a polymer hydrogel undergoing swelling. The gel microscopic dynamics exhibit a space dependence that strongly varies with time elapsed since the beginning of swelling. Initially, the dynamics in the periphery of the bead are much faster than in the core, indicative of nonuniform swelling. As the swelling proceeds, the dynamics slow down and become more spatially homogeneous. By comparing the experimental results to numerical and analytical calculations for the dynamics of a homogeneous, purely elastic sphere undergoing swelling, we establish that the mean square displacement of the gel strands deviates from the affine motion inferred from the macroscopic deformation, evolving from fast diffusivelike dynamics at the onset of swelling to slower, yet supradiffusive, rearrangements at later stages.

Structure Formation in Supraparticles Composed of Spherical and Elongated Particles

We studied the evaporation-induced formation of supraparticles from dispersions of elongated colloidal particles using experiments and computer simulations. Aqueous droplets containing a dispersion of ellipsoidal and spherical polystyrene particles were dried on superamphiphobic surfaces at different humidity values that led to varying evaporation rates. Supraparticles made from only ellipsoidal particles showed short-range lateral ordering at the supraparticle surface and random orientations in the interior regardless of the evaporation rate. Particle-based simulations corroborated the experimental observations in the evaporation-limited regime and showed an increase in the local nematic ordering as the diffusion-limited regime was reached. A thin shell of ellipsoids was observed at the surface when supraparticles were made from binary mixtures of ellipsoids and spheres. Image analysis revealed that the supraparticle porosity increased with an increasing aspect ratio of the ellipsoids.

Superhydrophobic Surface-Assisted Preparation of Microspheres and Supraparticles and Their Applications

Superhydrophobic surface (SHS) has been well developed, as SHS renders the property of minimizing the water/solid contact interface. Water droplets deposited onto SHS with contact angles exceeding 150°, allow them to retain spherical shapes, and the low adhesion of SHS facilitates easy droplet collection when tilting the substrate. These characteristics make SHS suitable for a wide range of applications. One particularly promising application is the fabrication of microsphere and supraparticle materials. SHS offers a distinct advantage as a universal platform capable of providing customized services for a variety of microspheres and supraparticles. In this review, an overview of the strategies for fabricating microspheres and supraparticles with the aid of SHS, including cross-linking process, polymer melting, and droplet template evaporation methods, is first presented. Then, the applications of microspheres and supraparticles formed onto SHS are discussed in detail, for example, fabricating photonic devices with controllable structures and tunable structural colors, acting as catalysts with emerging or synergetic properties, being integrated into the biomedical field to construct the devices with different medicinal purposes, being utilized for inducing protein crystallization and detecting trace amounts of analytes. Finally, the perspective on future developments involved with this research field is given, along with some obstacles and opportunities.

Challenges and strategies for commercialization and widespread practical applications of superhydrophobic surfaces

Superhydrophobic (SH) surfaces have progressed rapidly in fundamental research over the past 20 years, but their practical applications lag far behind. In this perspective, we first present the findings of a survey on the current state of SH surfaces including fundamental research, patenting, and commercialization. On the basis of the survey and our experience, this perspective explores the challenges and strategies for commercialization and widespread practical applications of SH surfaces. The comprehensive performances, preparation methods, and application scenarios of SH surfaces are the major constraints. These challenges should be addressed simultaneously, and the actionable strategies are provided. We then highlight the standard test methods of the comprehensive performances including mechanical stability, impalement resistance, and weather resistance. Last, the prospects of SH surfaces in the future are discussed. We anticipate that SH surfaces may be widely commercialized and used in practical applications around the year 2035 through combination of the suggested strategies and input from both academia and industry.

Communicating Supraparticles to Enable Perceptual, Information-Providing Matter

Materials are the fundament of the physical world, whereas information and its exchange are the centerpieces of the digital world. Their fruitful synergy offers countless opportunities for realizing desired digital transformation processes in the physical world of materials. Yet, to date, a perfect connection between these worlds is missing. From the perspective, this can be achieved by overcoming the paradigm of considering materials as passive objects and turning them into perceptual, information-providing matter. This matter is capable of communicating associated digitally stored information, for example, its origin, fate, and material type as well as its intactness on demand. Herein, the concept of realizing perceptual, information-providing matter by integrating customizable (sub-)micrometer-sized communicating supraparticles (CSPs) is presented. They are assembled from individual nanoparticulate and/or (macro)molecular building blocks with spectrally differentiable signals that are either robust or stimuli-susceptible. Their combination yields functional signal characteristics that provide an identification signature and one or multiple stimuli-recorder features. This enables CSPs to communicate associated digital information on the tagged material and its encountered stimuli histories upon signal readout anywhere across its life cycle. Ultimately, CSPs link the materials and digital worlds with numerous use cases thereof, in particular fostering the transition into an age of sustainability.

A double rigidity transition rules the fate of drying colloidal drops

The evaporation of drops of colloidal suspensions plays an important role in numerous contexts, such as the production of powdered dairies, the synthesis of functional supraparticles, and virus and bacteria survival in aerosols or drops on surfaces. The presence of colloidal particles in the evaporating drop eventually leads to the formation of a dense shell that may undergo a shape instability. Previous works propose that, for drops evaporating very fast, the instability occurs when the particles form a rigid porous solid, constituted of permanently aggregated particles at random close packing. To date, however, no measurements could directly test this scenario and assess whether it also applies to drops drying at lower evaporation rates, severely limiting our understanding of this phenomenon and the possibility of harnessing it in applications. Here, we combine macroscopic imaging and space- and time-resolved measurements of the microscopic dynamics of colloidal nanoparticles in drying drops sitting on a hydrophobic surface, measuring the evolution of the thickness of the shell and the spatial distribution and mobility of the nanoparticles. We find that, above a threshold evaporation rate, the drop undergoes successively two distinct shape instabilities, invagination and cracking. While permanent aggregation of nanoparticles accompanies the second instability, as hypothesized in previous works on fast-evaporating drops, we show that the first one results from a reversible glass transition of the shell, unreported so far. We rationalize our findings and discuss their implications in the framework of a unified state diagram for the drying of colloidal drops sitting on a hydrophobic surface.

Evaporation-driven Supraparticle Synthesis by Self-Lubricating Colloidal Dispersion Microdrops

The surface-templated evaporation-driven (S-TED) method that uses liquid-repellent surfaces has attracted considerable attention for its use in fabricating supraparticles of defined shape, size, and porosity. However, challenges in achieving mass production have impeded the widespread adoption of the S-TED method. To overcome this limit, we introduce an evaporation-driven "multiple supraparticle" synthesis by drying arrays of self-lubricating colloidal dispersion microdrops. To facilitate this synthetic method, a hydrophilic micropattern is prepared on a hydrophobic substrate as a template. During the removal of the substrate out of a dispersion, liquid drops are trapped and generate a microdrop array. To produce supraparticles, the contact lines of the trapped drops must be able to recede freely during evaporation. However, hydrophilic micropatterns induce strong contact line pinning for microdrops that hinders supraparticle formation. Herein, we solve this contradiction by employing an Ouzo-like colloidal dispersion, where we can control the wettability of the drop trapping domain. The self-lubrication effect provided by the Ouzo-like solution enables smooth movement of the drops' contact lines during evaporation, thereby resulting in the successful fabrication of supraparticle arrays even within the trapping domain. This strategy offers a promising and scalable approach for large-scale evaporation-driven supraparticle synthesis with a potential for extension to various primary colloidal particles, further broadening its applicability.

Self-Organization of Iron Sulfide Nanoparticles into Complex Multicompartment Supraparticles

Self-assembled compartments from nanoscale components are found in all life forms. Their characteristic dimensions are in 50-1000 nm scale, typically assembled from a variety of bioorganic "building blocks". Among the various functions that these mesoscale compartments carry out, protection of the content from the environment is central. Finding synthetic pathways to similarly complex and functional particles from technologically friendly inorganic nanoparticles (NPs) is needed for a multitude of biomedical, biochemical, and biotechnological processes. Here, it is shown that FeS2 NPs stabilized by l-cysteine self-assemble into multicompartment supraparticles (mSPs). The NPs initially produce ≈55 nm concave assemblies that reconfigure into ≈75 nm closed mSPs with ≈340 interconnected compartments with an average size of ≈5 nm. The intercompartmental partitions and mSP surface are formed primarily from FeS2 and Fe2 O3 NPs, respectively. The intermediate formation of cup-like particles enables encapsulation of biological cargo. This capability is demonstrated by loading mSPs with DNA and subsequent transfection of mammalian cells. Also it is found that the temperature stability of the DNA cargo is enhanced compared to the traditional delivery vehicles. These findings demonstrate that biomimetic compartmentalized particles can be used to successfully encapsulate and enhance temperature stability of the nucleic acid cargo for a variety of bioapplications.

Template-Directed Polymerization of Binary Acrylate Monomers on Surface-Activated Lignin Nanoparticles in Toughening of Bio-Latex Films

Fabricating bio-latex colloids with core-shell nanostructure is an effective method for obtaining films with enhanced mechanical characteristics. Nano-sized lignin is rising as a class of sustainable nanomaterials that can be incorporated into latex colloids. Fundamental knowledge of the correlation between surface chemistry of lignin nanoparticles (LNPs) and integration efficiency in latex colloids and from it thermally processed latex films are scarce. Here, an approach to integrate self-assembled nanospheres of allylated lignin as the surface-activated cores in a seeded free-radical emulsion copolymerization of butyl acrylate and methyl methacrylate is proposed. The interfacial-modulating function on allylated LNPs regulates the emulsion polymerization and it successfully produces a multi-energy dissipative latex film structure containing a lignin-dominated core (16% dry weight basis). At an optimized allyl-terminated surface functionality of 1.04 mmol g^-1 , the LNPs-integrated latex film exhibits extremely high toughness value above 57.7 MJ m^-3 . With multiple morphological and microstructural characterizations, the well-ordered packing of latex colloids under the nanoconfinement of LNPs in the latex films is revealed. It is concluded that the surface chemistry metrics of colloidal cores in terms of the abundance of polymerization-modulating anchors and their accessibility have a delicate control over the structural evolution of core-shell latex colloids.

From Meso to Macro: Controlling Hierarchical Porosity in Supraparticle Powders

A drying droplet containing colloidal particles can consolidate into a spherical assembly called a supraparticle. Such supraparticles are inherently porous due to the spaces between the constituent primary particles. Here, the emergent, hierarchical porosity in spray-dried supraparticles is tailored via three distinct strategies acting at different length scales. First, mesopores (<10 nm) are introduced via the primary particles. Second, the interstitial pores are tuned from the meso- (35 nm) to the macro scale (250 nm) by controlling the primary particle size. Third, defined macropores (>100 nm) are introduced via templating polymer particles, which can be selectively removed by calcination. Combining all three strategies creates hierarchical supraparticles with fully tailored pore size distributions. Moreover, another level of the hierarchy is added by fabricating supra-supraparticles, using the supraparticles themselves as building blocks, which provide additional pores with micrometer dimensions. The interconnectivity of the pore networks within all supraparticle types is investigated via detailed textural and tomographic analysis. This work provides a versatile toolbox for designing porous materials with precisely tunable, hierarchical porosity from the meso- (3 nm) to the macroscale (≈10 µm) that can be utilized for applications in catalysis, chromatography, or adsorption.

Evaporation-Driven Liquid-Liquid Crystalline Phase Separation in Droplets of Anisotropic Colloids

Drying a colloidal droplet involves complex physics that is often accompanied by evaporation-induced concentration gradients inside of the droplet, offering a platform for fundamental and technological opportunities, including self-assembly, thin film deposition, microfabrication, and DNA stretching. Here, we investigate the drying, liquid crystalline structures, and deposit patterns of colloidal liquid crystalline droplets undergoing liquid-liquid crystalline phase separation (LLCPS) during evaporation. We show that evaporation-induced progressive up-concentration inside the drying droplets makes it possible to cross, at different speeds, various thermodynamic stability states in solutions of amyloid fibril rigid filamentous colloids, thus allowing access to both metastable states, where phase separation occurs via nucleation and growth, as well as to unstable states, where phase separation occurs via the more elusive spinodal decomposition, leading to the formation of liquid crystalline microdroplets (or tactoids) of different shapes. We present the tactoids "phase diagram" as a function of the position within the droplet and elucidate their hydrodynamics. Furthermore, we demonstrate that the presence of the amyloid fibrils not only does not enhance the pinning behavior during droplet evaporation but also slightly suppresses it, thus minimizing the coffee-ring effect. We observed that microsize domains with cholesteric structure emerge in the drying droplet close to the droplet's initial edge, yet such domains are not connected to form a uniform cholesteric dried film. Finally, we demonstrate that a fully cholesteric dried layer can be generated from the drying droplets by regulating the kinetics of the evaporation process.

Highly porous gold supraparticles as surface-enhanced Raman spectroscopy (SERS) substrates for sensitive detection of environmental contaminants

Surface-enhanced Raman spectroscopy (SERS) has great potential as an analytical technique for environmental analyses. In this study, we fabricated highly porous gold (Au) supraparticles (i.e., ∼100 μm diameter agglomerates of primary nano-sized particles) and evaluated their applicability as SERS substrates for the sensitive detection of environmental contaminants. Facile supraparticle fabrication was achieved by evaporating a droplet containing an Au and polystyrene (PS) nanoparticle mixture on a superamphiphobic nanofilament substrate. Porous Au supraparticles were obtained through the removal of the PS phase by calcination at 500 °C. The porosity of the Au supraparticles was readily adjusted by varying the volumetric ratios of Au and PS nanoparticles. Six environmental contaminants (malachite green isothiocyanate, rhodamine B, benzenethiol, atrazine, adenine, and gene segment) were successfully adsorbed to the porous Au supraparticles, and their distinct SERS spectra were obtained. The observed linear dependence of the characteristic Raman peak intensity for each environmental contaminant on its aqueous concentration reveals the quantitative SERS detection capability by porous Au supraparticles. The limit of detection (LOD) for the six environmental contaminants ranged from ∼10 nM to ∼10 μM, which depends on analyte affinity to the porous Au supraparticles and analyte intrinsic Raman cross-sections. The porous Au supraparticles enabled multiplex SERS detection and maintained comparable SERS detection sensitivity in wastewater influent. Overall, we envision that the Au supraparticles can potentially serve as practical and sensitive SERS devices for environmental analysis applications.

A supraparticle-based biomimetic cascade catalyst for continuous flow reaction

Robust millimeter-sized spherical particles with controlled compositions and microstructures hold promises of important practical applications especially in relation to continuous flow cascade catalysis. However, the efficient fabrication methods for producing such particles remain scare. Here, we demonstrate a liquid marble approach to fabricate robust mm-sized porous supraparticles (SPs) through the bottom-up assembly of silica nanoparticles in the presence of strength additive or surface interactions, without the need for the specific liquid-repellent surfaces used by the existing methods. As the proof of the concept, our method was exemplified by fabricating biomimetic cascade catalysts through assembly of two types of well-defined catalytically active nanoparticles. The obtained SP-based cascade catalysts work well in industrially preferred fixed-bed reactors, exhibiting excellent catalysis efficiency, controlled reaction kinetics, high enantioselectivity (99% ee) and outstanding stability (200~500 h) in the cascades of ketone hydrogenation-kinetic resolution and amine racemization-kinetic resolution. The excellent catalytic performances are attributed to the structural features, reconciling close proximity of different catalytic sites and their sufficient spatial isolation.

Robust millimeter-sized spherical particles with controlled compositions and microstructures hold promises of important practical applications. Here the authors develop a liquid marble method to facilely fabricate robust millimeter-sized supraparticles with controlled microstructures through the bottom-up assembly of silica nanoparticles.

Highly Efficient and Controlled Fabrication of Supraparticles by Leidenfrost Phenomenon

Supraparticles (SPs) are agglomerates of smaller particles, which show promising applications in catalysis, sensing, and so forth. Preparation of SPs with controlled sizes, components, and structures in an efficient, scalable, and environmentally friendly way has become an urgent demand for the development of SPs. Herein, a method to fabricate SPs based on the Leidenfrost phenomenon is described. By dropping a nano-/microparticle dispersion on a metal plate at the Leidenfrost temperature (T_LF) or higher, the solvent evaporates quickly, and SPs can be formed within 1 min. To understand the influence of various factors on the properties of SPs, and also to optimize the fabrication of SPs, the effects of metal surface roughness and primary particle concentration on T_LF were carefully observed. Plates with a higher roughness as well as a higher primary particle concentration could trigger a lower T_LF. Combining the regulation of composition and volume of the droplets, SPs with different sizes, compositions, and structures were precisely fabricated. Furthermore, highly porous titanium dioxide (TiO₂) SPs with enhanced photocatalytic performance were fabricated via this method, showing the merits of the method in practical applications. This simple, efficient, and green method provides a new approach for controlled and large-scale fabrication of SPs with various functions.

Recording Temperature with Magnetic Supraparticles

Small-sized temperature indicator additives autonomously record temperature events via a gradual irreversible signal change. This permits, for instance, the indication of possible cold-chain breaches or failure of electronics but also curing of glues. Thus, information about the materials' thermal history can be obtained upon signal detection at every point of interest. In this work, maximum-temperature indicators with magnetic readout based on micrometer-sized supraparticles (SPs) are introduced. The magnetic signal transduction is, by nature, independent of the materials' optical properties. This facilitates the determination of valuable temperature information from the inside, that is, the bulk, even of dark and opaque macroscopic objects, which might differ from their surface. Compared to state-of-the-art optical temperature indicators, complementary magnetic readout characteristics ultimately expand their applicability. The conceptualized SPs are hierarchically structured assemblies of environmentally friendly, inexpensive iron oxide nanoparticles and thermoplastic polymer. Irreversible structural changes, induced by polymer softening, yield magnetic interaction changes within and between the hierarchic sub-structures, which are distinguishable and define the temperature indication mechanism. The fundamental understanding of the SPs' working principle enables customization of the particles' working range, response time, and sensitivity, using a toolbox-like manufacturing approach. The magnetic signal change is detected self-referenced, fast, and contactless.

Multi-compartment supracapsules made from nano-containers towards programmable release

The assembly of nanomaterials into suprastructures offers the possibility to fabricate larger scale functional materials, whose inner structure strongly influences their functionality for a vast range of applications. In spite of the many current strategies, achieving multi-compartment structures in a targeted and versatile way remains highly challenging. Here, we describe a controllable and straightforward route to create uniform suprastructured materials with a multi-compartmentalized architecture by confining primary nanocapsules into droplets using a cross-junction microfluidic device. Following solvent evaporation from the droplets, the nanocapsules spontaneously assemble into precisely sized multi-compartment particles, which we term supracapsules. Thanks to the process, each spatially separated nanocapsule unit retains its cargo and functionalities within the resulting supracapsules. However, new collective properties emerge, and, particularly, programmable release profiles that are distinct from those of single-compartment capsules. Finally, the suprastructures can be disassembled into single-compartment units by applying ultra-sonication, switching their release to a burst-release mode. These findings open up exciting opportunities to fabricate multi-compartment suprastructures incorporating diverse functionalities for materials with emerging properties.

Multimodal Enzyme-Carrying Suprastructures for Rapid and Sensitive Biocatalytic Cascade Reactions

Colloidal assemblies of mesoporous suprastructures provide effective catalysis in an advantageous volume-confined environment. However, typical fabrication methods of colloidal suprastructures are carried out under toxic or harmful conditions for unstable biomolecules, such as, biocatalytic enzymes. For this reason, biocatalytic enzymes have rarely been used with suprastructures, even though biocatalytic cascade reactions in confined environments are more efficient than in open conditions. Here, multimodal enzyme- and photocatalyst-carrying superstructures with efficient cascade reactions for colorimetric glucose detection are demonstrated. The suprastructures consisting of various functional nanoparticles, including enzyme-carrying nanoparticles, are fabricated by surface-templated evaporation driven suprastructure synthesis on polydimethylsiloxane-grafted surfaces at ambient conditions. For the fabrication of suprastructures, no additional chemicals and reactions are required, which allows maintaining the enzyme activities. The multimodal enzymes (glucose oxidase and peroxidase)-carrying suprastructures exhibit rapid and highly sensitive glucose detection via two enzyme cascade reactions in confined geometry. Moreover, the combination of enzymatic and photocatalytic cascade reactions of glucose oxidase to titanium dioxide nanoparticles is successfully realized for the same assay. These results show promising abilities of multiple colloidal mixtures carrying suprastructures for effective enzymatic reactions and open a new door for advanced biological reactions and enzyme-related works.

Spray-Drying and Atomic Layer Deposition: Complementary Tools toward Fully Orthogonal Control of Bulk Composition and Surface Identity of Multifunctional Supraparticles

Spray-drying is a scalable process enabling one to assemble freely chosen nanoparticles into supraparticles. Atomic layer deposition (ALD) allows for controlled thin film deposition of a vast variety of materials including exotic ones that can hardly be synthesized by wet chemical methods. The properties of coated supraparticles are defined not only by the nanoparticle material chosen and the nanostructure adjusted during spray-drying but also by surface functionalities modified by ALD, if ALD is capable of modifying not only the outer surfaces but also surfaces buried inside the porous supraparticle. Simultaneously, surface accessibility in the porous supraparticles must be ensured to make use of all functionalized surfaces. In this work, iron oxide supraparticles are utilized as a model substrate as their magnetic properties enable the use of advanced magnetic characterization methods. Detailed information about the structural evolution upon individual ALD cycles of aluminium oxide, zinc oxide and titanium dioxide are thereby revealed and confirmed by gas sorption analyses. This demonstrates a powerful and versatile approach to freely designing the functionality of future materials by combination of spray-drying and ALD.

Textured and Hierarchically Constructed Polymer Micro- and Nanoparticles

Microfluidic techniques allow for the tailored construction of specific microparticles, which are becoming increasingly interesting and relevant. Here, using a microfluidic hole-plate-device and thermal-initiated free radical polymerization, submicrometer polymer particles with a highly textured surface were synthesized. Two types of monomers were applied: (1) methylmethacrylate (MMA) combined with crosslinkers and (2) divinylbenzene (DVB). Surface texture and morphology can be influenced by a series of parameters such as the monomer–crosslinker–solvent composition, surfactants, and additives. Generally, the most structured surfaces with the simultaneously most uniform particles were obtained in the DVB–toluene–nonionic-tensides system. In a second approach, poly-MMA (PMMA) particles were used to build aggregates with bigger polymer particles. For this purpose, tripropyleneglycolediacrylate (TPGDA) particles were synthesized in a microfluidic co-flow arrangement and polymerized by light- irradiation. Then, PMMA particles were assembled at their surface. In a third step, these composites were dispersed in an aqueous acrylamide–methylenebisacrylamide solution, which again was run through a co-flow-device and photopolymerized. As such, entities consisting of particles of three different size ranges—typically 0.7/30/600 µm—were obtained. The particles synthesized by both approaches are potentially suitable for loading with or incorporation of analytic probes or catalysts such as dyes or metals.

Influence of Surfactant-Mediated Interparticle Contacts on the Mechanical Stability of Supraparticles

Colloidal supraparticles are micron-scale spherical assemblies of uniform primary particles, which exhibit emergent properties of a colloidal crystal, yet exist as a dispersible powder. A prerequisite to utilize these emergent functionalities is that the supraparticles maintain their mechanical integrity upon the mechanical impacts that are likely to occur during processing. Understanding how the internal structure relates to the resultant mechanical properties of a supraparticle is therefore of general interest. Here, we take the example of supraparticles templated from water/fluorinated oil emulsions in droplet-based microfluidics and explore the effect of surfactants on their mechanical properties. Stable emulsions can be generated by nonionic block copolymers consisting of a hydrophilic and fluorophilic block and anionic fluorosurfactants widely available under the brand name Krytox. The supraparticles formed in the presence of both types of surfactants appear structurally similar, but differ greatly in their mechanical properties. While the nonionic surfactant induces superior mechanical stability and ductile fracture behavior, the anionic Krytox surfactant leads to weak supraparticles with brittle fracture. We complement this macroscopic picture with Brillouin light spectroscopy that is very sensitive to the interparticle contacts for subnanometer-thick adsorbed layers atop of the nanoparticle. While the anionic Krytox does not significantly affect the interparticle bonds, the amphiphilic nonionic surfactant drastically strengthens these bonds to the point that individual particle vibrations are not resolved in the experimental spectrum. Our results demonstrate that seemingly subtle changes in the physicochemical properties of supraparticles can drastically impact the resultant mechanical properties.

Mechanics of colloidal supraparticles under compression

Colloidal supraparticles are finite, spherical assemblies of many primary particles. To take advantage of their emergent functionalities, such supraparticles must retain their structural integrity. Here, we investigate their size-dependent mechanical properties via nanoindentation. We find that the deformation resistance inversely scales with the primary particle diameter, while the work of deformation is dependent on the supraparticle diameter. We adopt the Griffith theory to such particulate systems to provide a predictive scaling to relate the fracture stress to the geometry of supraparticles. The interplay between primary particle material and cohesive interparticle forces dictates the mechanical properties of supraparticles. We find that enhanced stability, associated with ductile fracture, can be achieved if supraparticles are engineered to dissipate more energy via deformation of primary particles than breaking of interparticle bonds. Our work provides a coherent framework to analyze, predict, and design the mechanical properties of colloidal supraparticles.

Controlling supraparticle shape and structure by tuning colloidal interactions

HYPOTHESIS

Assembly of colloids in drying colloidal suspensions on superhydrophobic surface is influenced by the colloidal interactions, which determine the shape and interior structure of the assembled supraparticle. The introduction of salt (electrolyte) into the assembly system is expected to influence the colloid interactions and packing during the evaporation process. Hence, both the outer shape and internal structure of supraparticles should be controlled by varying salt concentrations.

EXPERIMENTS

Suspensions of electrostatically stabilized polystyrene particles with specified salt concentrations were chosen as model systems to conduct the evaporation on a superhydrophobic surface. A systematic study was performed by regulating the concentration and valency of salt. The morphology and interior of supraparticles were carefully characterized with electron scanning microscopy, while the colloidal interaction was established using colloidal probe atomic force microscopy.

FINDINGS

Supraparticles displayed a spherical-to-nonspherical shape change due to the addition of salts. The extent of crystallization depended on salt concentration. These changes in shape and structure were correlated with salt-dependent single colloid interaction forces, which were not previously investigated in detail in radially symmetric evaporation geometry. Our findings are crucial for understanding assembly behavior during the drying process and offer guidance for preparing complex supraparticles to meet specific applications requirement.

Polymeric Microparticles Generated via Confinement-Free Fluid Instability

In-fiber fluid instability can be harnessed to realize scalable microparticles fabrication with tunable sizes and multifunctional characteristics making it competitive in comparison to conventional microparticles fabrication methods. However, since in-fiber fluid instability has to be induced via thermal annealing and the resulting microparticles can only be collected after dissolving the fiber cladding, obtaining contamination-free particles for high-temperature incompatible materials remains great challenge. Herein, confinement-free fluid instability is demonstrated to fabricate polymeric microparticles in a facile manner induced by the ultralow surface energy of the superamphiphobic surface. The polymer solution columns break up into uniform droplets then form spherical particles spontaneously in seconds at ambient temperature. This method can be applied to a variety of polymers spanning an exceptionally wide range of sizes: from 1 mm down to 1 µm. With the aid of microfluidic spinning instrument, a large quantity of microparticles can be obtained, making this method promising for scaling up production. Notably, through simple modification of the feed solution configuration, composite/structured micromaterials can also be produced, including quantum-dots-labeled fluorescent particles, magnetic particles, core-shell particles, microcapsules, and necklace-like microfibers. This method, with general applicability and facile control, is envisioned to have great prospects in the field of polymer microprocessing.

Lignin-Based Porous Supraparticles for Carbon Capture

Multiscale carbon supraparticles (SPs) are synthesized by soft-templating lignin nano- and microbeads bound with cellulose nanofibrils (CNFs). The interparticle connectivity and nanoscale network in the SPs are studied after oxidative thermostabilization of the lignin/CNF constructs. The carbon SPs are formed by controlled sintering during carbonization and develop high mechanical strength (58 N·mm^-3) and surface area (1152 m²·g^-1). Given their features, the carbon SPs offer hierarchical access to adsorption sites that are well suited for CO₂ capture (77 mg CO₂·g^-1), while presenting a relatively low pressure drop (∼33 kPa·m^-1 calculated for a packed fixed-bed column). The introduced lignin-derived SPs address the limitations associated with mass transport (diffusion of adsorbates within channels) and kinetics of systems that are otherwise based on nanoparticles. Moreover, the carbon SPs do not require doping with heteroatoms (as tested for N) for effective CO₂ uptake (at 1 bar CO₂ and 40 °C) and are suitable for regeneration, following multiple adsorption/desorption cycles. Overall, we demonstrate porous SP carbon systems of low cost (precursor, fabrication, and processing) and superior activity (gas sorption and capture).

Designing the shape of supraparticles by controlling the apparent contact angle and contact line friction of droplets

Surface-templated evaporation-driven supraparticle synthesis is a versatile method for supraparticle fabrication. A supraparticle is formed by drying droplet of a colloidal dispersion on liquid repellent surfaces, allowing precise control of the size and mean composition of the supraparticles. The crucial factor determining the morphology is the motion of the contact line of the dispersion droplet on the liquid repellent surface. Here, we study effects of (i) the apparent contact angle and (ii) the contact line friction of a droplet on the shape of the supraparticle. In order to change the initial apparent contact angle of the dispersion droplet a surfactant was added to decrease surface tension. In addition, two different liquid repellent surfaces were used: a polydimethysiloxane (PDMS) grafted surface and a lubricated surface. Both surfaces exhibited distinctly different contact line friction during evaporation. As the initial contact angle of a droplet decreases and friction of a contact line increases, flatter supraparticles are fabricated. By using this simple manipulation principle, eventually, various shapes of supraparticles can be obtained, such as mushroom, hemispherical, convex lens, and disk shapes. This study presents fundamental and critical information that allow us to manipulate the shape of a supraparticle via surface-templated evaporation-driven synthesis that increases the scalability of supraparticles for use in a wide range of applications.

Particle Size Determines the Shape of Supraparticles in Self-Lubricating Ternary Droplets

Supraparticles are large clusters of much smaller colloidal particles. Controlling the shape and anisotropy of supraparticles can enhance their functionality, enabling applications in fields such as optics, magnetics, and medicine. The evaporation of self-lubricating colloidal ouzo droplets is an easy and efficient strategy to create supraparticles, overcoming the problem of the "coffee-stain effect" during drop evaporation. Yet, the parameters that control the shape of the supraparticles formed in such evaporating droplets are not fully understood. Here, we show that the size of the colloidal particles determines the shape of the supraparticle. We compared the shape of the supraparticles made of seven different sizes of spherical silica particles, namely from 20 to 1000 nm, and of the mixtures of small and large colloidal particles at different mixing ratios. Specifically, our in situ measurements revealed that the supraparticle formation proceeds via the formation of a flexible shell of colloidal particles at the rapidly moving interfaces of the evaporating droplet. The time t_c0 when the shell ceases to shrink and loses its flexibility is closely related to the size of particles. A lower t_c0, as observed for smaller colloidal particles, leads to a flat pancake-like supraparticle, in contrast to a more curved American football-like supraparticle from larger colloidal particles. Furthermore, using a mixture of large and small colloidal particles, we obtained supraparticles that display a spatial variation in particle distribution, with small colloids forming the outer surface of the supraparticle. Our findings provide a guideline for controlling the supraparticle shape and the spatial distribution of the colloidal particles in supraparticles by simply self-lubricating ternary drops filled with colloidal particles.

Self-assembled mesostructured Co0.5Fe2.5O4 nanoparticle superstructures for highly efficient oxygen evolution

Self-assembly of colloidal nanoparticles (NPs) into well-defined superstructures has been recognized as one of the most promising ways to fabricate rationally-designed functional materials for a variety of applications. Introducing hierarchical mesoporosity into NP superstructures will facilitate mass transport while simultaneously enhancing the accessibility of constituent NPs, which is of critical importance for widening their applications in catalysis and energy-related fields. Herein, we develop a colloidal co-assembly strategy to construct mesostructured, carbon-coated Co_0.5Fe_2.5O₄ NP superstructures (M-C@CFOSs), which show great promise as highly efficient electrocatalysts for the oxygen evolution reaction (OER). Specifically, organically-stabilized SiO₂ NPs are employed as both building blocks and sacrificial template, which co-assemble with Co_0.5Fe_2.5O₄ NPs to afford binary NP superstructures through a solvent drying process. M-C@CFOSs are obtainable after in situ ligand carbonization followed by the selective removal of SiO₂ NPs. The hierarchical mesoporous structure of M-C@CFOSs, combined with the conformal graphitic carbon coating derived from the native organic ligands, significantly improves their electrocatalytic performance as OER electrocatalysts when compared with nonporous Co_0.5Fe_2.5O₄ NP superstructures. This work establishes a new and facile approach for designing NP superstructures with hierarchical mesoporosity, which may find wide applications in energy storage and conversion.

Controlling the Large-Scale Fabrication of Supraparticles

Controlling the nanoscale interactions of colloidal building blocks is a key step for the transition from single nanoparticles to tailor-made, architected morphologies and their further integration into functional materials. Solvent evaporation-induced self-assembly within emulsion droplets emerges as a fast, versatile, and low-cost approach to obtain spherical, complex structures, such as supraparticles. Nevertheless, some process-structure relationships able to describe the effects of emulsion conditions on the synthesis outcomes still remain to be understood. Here, we explore the effect of different physicochemical parameters of emulsion-templated self-assembly (ETSA) on supraparticles' formation. Supraparticle size, size dispersity, microporosity, and sample homogeneity are rationalized based on the used surfactant formulation, stabilization mechanism, and viscosity of the emulsion. We further demonstrate the significance of the parameters found by optimizing a transferable, large-scale (gram-size) ETSA setup for the controlled synthesis of spherical supraparticles in a range of defined sizes (from 0.1-10 μm). Ultimately, our results provide new key synthetic parameters able to control the process, promoting the development of supraparticle-based, functional nanomaterials for a wide range of applications.

Stratification of polymer mixtures in drying droplets: Hydrodynamics and diffusion

We study the evaporation-induced stratification of a mixture of short and long polymer chains in a drying droplet using molecular simulations. We systematically investigate the effects of hydrodynamic interactions (HI) on this process by comparing hybrid simulations accounting for HI between polymers through the multiparticle collision dynamics technique with free-draining Langevin dynamics simulations neglecting the same. We find that the dried supraparticle morphologies are homogeneous when HI are included but are stratified in core-shell structures (with the short polymers forming the shell) when HI are neglected. The simulation methodology unambiguously attributes this difference to the treatment of the solvent in the two models. We rationalize the presence (or absence) of stratification by measuring phenomenological multicomponent diffusion coefficients for the polymer mixtures. The diffusion coefficients show the importance of not only solvent backflow but also HI between polymers in controlling the dried supraparticle morphology.