Development of a colloidal lithography method for patterning nonplanar surfaces

Superhydrophilic Coating of Pine Wood by Plasma Functionalization of Self-Assembled Polystyrene Spheres

Self-assembling films typically used for colloidal lithography have been applied to pine wood substrates to change the surface wettability. Therefore, monodisperse polystyrene (PS) spheres have been deposited onto a rough pine wood substrate via dip coating. The resulting PS sphere film resembled a polycrystalline face centered cubic (FCC)-like structure with typical domain sizes of 5–15 single spheres. This self-assembled coating was further functionalized via an O2 plasma. This plasma treatment strongly influenced the particle sizes in the outermost layer, and hydroxyl as well as carbonyl groups were introduced to the PS spheres’ surfaces, thus generating a superhydrophilic behavior.

Compensation of disorder for extraordinary optical transmission effect in nanopore arrays fabricated by nanosphere photolithography

The work considers the effect of extraordinary optical transmission (EOT) in polycrystalline arrays of nanopores fabricated via nanosphere photolithography (NPL). The use of samples with different qualities of polycrystalline structure allows us to reveal the role of disorder for EOT. We propose a phenomenological model which takes the disorder into account in numerical simulations and validate it using experimental data. Due to the NPL flexibility for the structure geometry control, we demonstrate the possiblity to partially compensate the disorder influence on EOT by the nanopore depth adjustments. The proposed experimental and theoretical results are promising to reveal the NPL limits for EOT-based devices and stimulate systematic studies of disorder compensation designs.

Pattern detection in colloidal assembly: A mosaic of analysis techniques

Characterization of the morphology, identification of patterns and quantification of order encountered in colloidal assemblies is essential for several reasons. First of all, it is useful to compare different self-assembly methods and assess the influence of different process parameters on the final colloidal pattern. In addition, casting light on the structures formed by colloidal particles can help to get better insight into colloidal interactions and understand phase transitions. Finally, the growing interest in colloidal assemblies in materials science for practical applications going from optoelectronics to biosensing imposes a thorough characterization of the morphology of colloidal assemblies because of the intimate relationship between morphology and physical properties (e.g. optical and mechanical) of a material. Several image analysis techniques developed to investigate images (acquired via scanning electron microscopy, digital video microscopy and other imaging methods) provide variegated and complementary information on the colloidal structures under scrutiny. However, understanding how to use such image analysis tools to get information on the characteristics of the colloidal assemblies may represent a non-trivial task, because it requires the combination of approaches drawn from diverse disciplines such as image processing, computational geometry and computational topology and their application to a primarily physico-chemical process. Moreover, the lack of a systematic description of such analysis tools makes it difficult to select the ones more suitable for the features of the colloidal assembly under examination. In this review we provide a methodical and extensive description of real-space image analysis tools by explaining their principles and their application to the investigation of two-dimensional colloidal assemblies with different morphological characteristics.

Controlling the Interparticular Distances of Extended Non-Close-Packed Colloidal Monolayers

A versatile method for the preparation extended, well-ordered, non-close-packed monolayers of silica nanoparticles (137 ± 4 nm diameter) with adjustable interparticle distances is presented, which is based on a simple self-assembly procedure using aqueous dispersion with different ionic strengths. It is shown that these structures can be successfully transferred to air without suffering from aggregation. Scanning electron microscopy (SEM) is used to characterize the structures after transfer into the atmosphere. These investigations were combined with a quartz crystal microbalance with dissipation (QCM-D) experiments to follow the self-assembly process in solution. The nearest-neighbor distance distribution reveals a monotonous decrease of the average nearest-neighbor distance from 290 to 200 nm with increasing ionic strength from 0.05 to 1 mM, which indicates an increased shielding of the electrostatic interaction with increasing ionic strength. The observed saturation coverages for all studied ionic strengths are well explained with an effective hard-sphere model in which the saturation coverage is limited by Coulomb repulsion. However, at ionic strengths above 1 mM, significant amounts of aggregates are found in the dried samples, suggesting that the observed aggregates at high ionic strengths are formed during the drying process caused by capillary forces between the particles. Tuning the barrier for lateral diffusion, e.g., by changing the surface morphology or functionalization of the particles will offer a route to further extend the range of particle distances. The present approach can be easily expanded to a broad range of colloidal materials on surfaces, while it only requires low-cost laboratory equipment.

Direct etching at the nanoscale through nanoparticle-directed capillary condensation

We report a method to locally deliver a chemical etchant at the nanoscale in the vapor phase by capillary condensation forming a meniscus at the nanoparticle/substrate interface. The process is simple, scalable and does not require functionalization of the nanoparticles. Furthermore, it does not rely on any specific chemical properties of the materials other than the solution being aqueous and the wettability properties of the surfaces involved, which should enable its application to other material and chemical combinations. In particular, in this work we demonstrate the proposed process by periodically pattering a SiO₂ layer using a self-assembled monolayer of polystyrene particles exposed to HF vapors. The patterned SiO₂ layer is then used as a mask to etch a pattern of inverted nanopyramids on Si. The silicon nanopatterning has been demonstrated for particles sizes ranging from 800 nm down to 100 nm, providing pyramids with a size down to 50 nm for 100 nm nanoparticles.

Interaction-tailored organization of large-area colloidal assemblies

Colloidal lithography is an innovative fabrication technique employing spherical, nanoscale crystals as a lithographic mask for the low cost realization of nanoscale patterning. The features of the resulting nanostructures are related to the particle size, deposition conditions and interactions involved. In this work, we studied the absorption of polystyrene spheres onto a substrate and discuss the effect of particle-substrate and particle-particle interactions on their organization. Depending on the nature and the strength of the interactions acting in the colloidal film formation, two different strategies were developed in order to control the number of particles on the surface and the interparticle distance, namely changing the salt concentration and absorption time in the particle solution. These approaches enabled the realization of large area (≈cm2) patterning of nanoscale holes (nanoholes) and nanoscale disks (nanodisks) of different sizes and materials.

Spun-wrapped aligned nanofiber (SWAN) lithography for fabrication of micro/nano-structures on 3D objects

Fabrication of micro/nano-structures on irregularly shaped substrates and three-dimensional (3D) objects is of significant interest in diverse technological fields. However, it remains a formidable challenge thwarted by limited adaptability of the state-of-the-art nanolithography techniques for nanofabrication on non-planar surfaces. In this work, we introduce Spun-Wrapped Aligned Nanofiber (SWAN) lithography, a versatile, scalable, and cost-effective technique for fabrication of multiscale (nano to microscale) structures on 3D objects without restriction on substrate material and geometry. SWAN lithography combines precise deposition of polymeric nanofiber masks, in aligned single or multilayer configurations, with well-controlled solvent vapor treatment and etching processes to enable high throughput (>10(-7) m(2) s(-1)) and large-area fabrication of sub-50 nm to several micron features with high pattern fidelity. Using this technique, we demonstrate whole-surface nanopatterning of bulk and thin film surfaces of cubes, cylinders, and hyperbola-shaped objects that would be difficult, if not impossible to achieve with existing methods. We demonstrate that the fabricated feature size (b) scales with the fiber mask diameter (D) as b(1.5)∝D. This scaling law is in excellent agreement with theoretical predictions using the Johnson, Kendall, and Roberts (JKR) contact theory, thus providing a rational design framework for fabrication of systems and devices that require precisely designed multiscale features.

Highly conformal fabrication of nanopatterns on non-planar surfaces

While the number of techniques for patterning materials at the nanoscale exponentially increases, only a handful of methods approach the conformal patterning of strongly non-planar surfaces. Here, using the direct surface self-assembly of colloids by electrostatics, we produce highly conformal bottom-up nanopatterns with a short-range order. We illustrate the potential of this approach by devising functional nanopatterns on highly non-planar substrates such as pyramid-textured silicon substrates and inherently rough polycrystalline films. We further produce functionalized polycrystalline thin-film silicon solar cells with enhanced optical performance. The perspective presented here to pattern essentially any surface at the nanoscale, in particular surfaces with high inherent roughness or with microscale features, opens new possibilities in a wide range of advanced technologies from affordable photovoltaics and optoelectronics to cellular engineering.

Controlling the Interaction and Non-Close-Packed Arrangement of Nanoparticles on Large Areas

In light of the importance of nanostructured surfaces for a variety of technological applications, the quest for simple and reliable preparation methods of ordered, nanometer ranged structures is ongoing. Herein, a versatile method to prepare ordered, non-close-packed arrangements of nanoparticles on centimeter sized surfaces by self-assembly is described using monodisperse (118-162 nm Ø), amino-functionalized silica nanoparticles as an exploratory example. It is shown that the arrangement of the particles is governed by the interplay between the electrostatic repulsion between the particles and the interaction between particles and surfaces. The latter is tuned by the properties of the particles such as their surface roughness as well as the chemistry of the linkage. Weak dispersive interactions between amino groups and gold surfaces are compared to a covalent amide linkage of the amino groups with carboxylic acid functionalized self-assembled monolayers. It was shown that the order of the former systems may suffer from capillary forces between particles during the drying process, while the covalently bonded systems do not. In turn, covalently bonded systems can be dried quickly, while the van der Waals bonded systems require a slow drying process to minimize aggregation. These highly ordered structures can be used as templates for the formation of a second, ordered, non-close-packed layer of nanoparticles exemplified for larger polystyrene particles (Ø 368 ± 14 nm), which highlights the prospect of this approach as a simple preparation method for ordered arrays of nanoparticles with tunable properties.

Monolayers of charged particles in a Langmuir trough: Could particle aggregation increase the surface pressure?

The effect of aggregation on the surface pressure, Π, of monolayers from charged micrometer-sized colloidal particles on the air/water interface is investigated. Π is completely due to the long-range electrostatic repulsion between the particles mediated by their electrostatic field in the air. The most probable origin of particle aggregation is the attraction between capillary quadrupoles due to undulated contact lines on particle surfaces. Aggregates have higher charge and repel each other stronger than single particles. The data analysis by means of a theoretical model implies that Π linearly increases with n(1/2); n is the mean aggregation number, which can be determined from the experimental Π vs. area curves. The presence of electrolyte promotes aggregation, which tends to increase Π, but simultaneously reduces the surface charge that leads to lower Π. For our system, the first effect prevails and apparently paradoxical behavior is observed: the addition of salt in water enhances the electrostatic surface pressure. The data indicate limited aggregation: the rise of the electrostatic barrier prevents the further coalescence of aggregates if they have become sufficiently large. The results contribute for a better understanding of the factors that control the interactions in monolayers of charged particles at liquid interfaces.

Rapid nanostructuration of polymer colloid surfaces by nonsolvent induced phase separation

We have designed an effective strategy for producing nanostructures on the polymer colloid surfaces within few minutes. The poly(N-vinylpyrrolidone) (PVP)-stabilized polystyrene colloid latex dispersed in ethanol was exposed to a nonsolvent medium of PVP and nanometric droplets formed on the polymer colloid surfaces within few minutes. Surface wettability of the polymer colloids with nanoprotrusions experienced a significant change as compared with the smooth polymer colloids. The formation mechanism was ascribed to the precipitation of PVP phase due to the nonsolvent induced phase separation. To further confirm the proposed mechanism, the material components included in the polymer colloid lattices before the nanostructuration process and surface compositions on the nanostructured polymer colloid surfaces were characterized using gel permeation chromatography (GPC) and time-of-flight secondary ion mass spectrometry (TOF-SIMS) respectively. This new strategy provides an alternative and promising method for patterning curved polymer surfaces. The polymer colloids with different surface textures would be ideal for use as model systems in biomedical research such as targets in phagocytosis and platforms of drug delivery.

Fabrication of planar colloidal clusters with template-assisted interfacial assembly

The synthesis of nanoparticle clusters, also referred to as colloidal clusters or colloidal molecules, is being studied intensively as a model system for small molecule interactions as well as for the directed self-assembly of advanced materials. This paper describes a technique for the interfacial assembly of planar colloidal clusters using a combination of top-down lithographic surface modification and bottom-up Langmuir-Blodgett deposition. Micrometer sized polystyrene latex particles were deposited onto a chemically modified substrate from a decane-water interface with Langmuir-Blodgett deposition. The surface of the substrate contained hydrophilic domains of various size, spacing, and shape, while the remainder of the substrate was hydrophobic. Particles selectively deposited onto hydrophilic regions from the decane-water interface. The number of deposited particles depended on the size of each patch, thereby demonstrating that tuning cluster size is possible by engineering patch geometry. Following deposition, the clusters were permanently bonded with temperature annealing and then removed from the substrate via sonication. The permanently bonded planar colloidal clusters were stable in an aqueous environment and at a decane-water interface laden with isotropic colloidal particles. The method is a simple and fast way to synthesize colloidal clusters with few limitations on particle chemistry, composition, and shape.

Nanotopographical Surfaces for Stem Cell Fate Control: Engineering Mechanobiology from the Bottom

During embryogenesis and tissue maintenance and repair in an adult organism, a myriad of stem cells are regulated by their surrounding extracellular matrix (ECM) enriched with tissue/organ-specific nanoscale topographical cues to adopt different fates and functions. Attributed to their capability of self-renewal and differentiation into most types of somatic cells, stem cells also hold tremendous promise for regenerative medicine and drug screening. However, a major challenge remains as to achieve fate control of stem cells in vitro with high specificity and yield. Recent exciting advances in nanotechnology and materials science have enabled versatile, robust, and large-scale stem cell engineering in vitro through developments of synthetic nanotopographical surfaces mimicking topological features of stem cell niches. In addition to generating new insights for stem cell biology and embryonic development, this effort opens up unlimited opportunities for innovations in stem cell-based applications. This review is therefore to provide a summary of recent progress along this research direction, with perspectives focusing on emerging methods for generating nanotopographical surfaces and their applications in stem cell research. Furthermore, we provide a review of classical as well as emerging cellular mechano-sensing and -transduction mechanisms underlying stem cell nanotopography sensitivity and also give some hypotheses in regard to how a multitude of signaling events in cellular mechanotransduction may converge and be integrated into core pathways controlling stem cell fate in response to extracellular nanotopography.

Nanotopographic Biomaterials for Isolation of Circulating Tumor Cells

Circulating tumor cells (CTCs) shed from the primary tumor mass and circulating in the bloodstream of patients are believed to be vital to understand of cancer metastasis and progression. Capture and release of CTCs for further enumeration and molecular characterization holds the key for early cancer diagnosis, prognosis and therapy evaluation. However, detection of CTCs is challenging due to their rarity, heterogeneity and the increasing demand of viable CTCs for downstream biological analysis. Nanotopographic biomaterial-based microfluidic systems are emerging as promising tools for CTC capture with improved capture efficiency, purity, throughput and retrieval of viable CTCs. This review offers a brief overview of the recent advances in this field, including CTC detection technologies based on nanotopographic biomaterials and relevant nanofabrication methods. Additionally, the possible intracellular mechanisms of the intrinsic nanotopography sensitive responses that lead to the enhanced CTC capture are explored.

Colloidal pattern replication through contact photolithography operated in a 'Talbot-Fabry-Perot' regime

We describe a method for continuous colloidal pattern replication using contact photolithography. Cr-on-quartz masks are fabricated using colloidal nanosphere lithography and subsequently used as photolithography stamps. Hexagonal pattern arrangements with different dimensions (980, 620 and 480 nm, using colloidal particles with these respective diameters) have been studied. When the mask and the imaged resist layer were in intimate contact, a high fidelity pattern replica was obtained after photolithographic exposure and processing. In turn, the presence of an air gap in between was found to affect the projected image on the photoresist layer, with a strong dependence on the mask feature size and height of the air gap. Pattern replication, inversion and hybridization were achieved for the 980 nm period mask; no hybridization for the 620 nm one; and only pattern replication for the 480 nm one. These results are interpreted in the framework of a 'Talbot-Fabry-Perot' effect. Numerical simulations corroborate the experimental findings, providing insight into the processes involved and highlighting the important parameters affecting the exposure pattern. This approach allows complex subwavelength patterning and is relevant for three-dimensional layer-by-layer printing.

Surface pressure isotherm for a monolayer of charged colloidal particles at a water/nonpolar-fluid interface: experiment and theoretical model

Monolayers from electrically charged micrometer-sized silica particles, spread on the air/water interface, are investigated. Because of the electrostatic repulsion, the distances between the particles are considerably greater than their diameters, i.e., we are dealing with nondensely packed interfacial layers. The electrostatic repulsion between the particles occurs through the air phase. Surface pressure vs area isotherms were measured by Langmuir trough, and the monolayers' morphology was monitored by microscope. The mean area per particle is determined by Delaunay triangulation and Voronoi diagrams. In terms of mean area, the surface pressure for monolayers from polydisperse and monodisperse particles obeys the same law. The experiments show that Π ∝ L(-3) at large L, where Π is the surface pressure and L is the mean interparticle distance. A theoretical cell model is developed, which predicts not only the aforementioned asymptotic law but also the whole Π(L) dependence. The model presumes a periodic distribution of the surface charge density, which induces a corresponding electric field in the air phase. Then, the Maxwell pressure tensor of the electric field in the air phase is calculated and integrated according to the Bakker's formula to determine the surface pressure. Thus, all collective effects from the electrostatic interparticle interactions are taken into account as well as the effects from the particle finite size. By evaporation of water, the particle monolayers are deposited on a solid substrate placed on the bottom of the trough. The electrostatic interparticle repulsion is strong enough to withstand the attractive lateral capillary immersion forces that are operative during the drying of the monolayer on the substrate. The obtained experimental results and the developed theoretical model can be useful for prediction and control of the properties of nondensely packed interfacial monolayers from charged particles that find applications for producing micropatterned surfaces.

Photochemistry-based method for the fabrication of SnO(2) monolayer ordered porous films with size-tunable surface pores for direct application in resistive-type gas sensor

A new photochemistry-based method was introduced for fabricating SnO2 monolayer ordered porous films with size-tunable surface pores on ceramic tubes used for gas sensors. The growth of the spherical pore walls was controlled by two times irradiation of the ultraviolet light using polystyrene microsphere two-dimensional colloidal crystal as a template. The surface pore size of the final obtained porous films was well tuned by changing the second irradiation time rather than replacing the template microspheres. The monolayer ordered porous films on the tubes were directly used, for the first time, as gas sensors. The sensitivity of the sensor depended on the surface pore size and was carefully analyzed by ethanol gas detection. The sensor also exhibited short response-recovery time and long-term stability at lower than 300 °C in practical applications. Therefore, this study opens up a kind of construction method for gas sensors, provides a new strategy for controlling the surface pore size of the monolayer ordered porous film, and introduces a new type of sensitivity-controllable gas sensor.

Facile colloidal lithography on rough and non-planar surfaces for asymmetric patterning

Free-standing colloidal arrays can be easily transferred to supported fibers. These films conform and provide the template to have consistent submicrometer and nanometer features transferred to the periphery of rough, 7 μm diameter fibers. This technique is adjustable to a number of fiber surfaces and colloidal template sizes.

Tunable assembly of colloidal crystal alloys using magnetic nanoparticle fluids

We demonstrate a magnetic technique for assembling bidisperse and tridisperse colloidal particle fluids into a variety of complex structures with dimensionality ranging from 0-D (rings) to 1-D (chains) to 2-D (tiles). Compared with prior work on bidisperse particles that are commensurate in size, here we explore the assembly of different sized particles, and we show that due to packing constraints, new particle structures can be realized experimentally. Extending these experiments to a tridisperse system, we demonstrate that at low concentrations the smallest particle does not change the underlying crystal structures of the bidisperse system; however, it can assist in the formation of crystallite structures that were not stable in a bidisperse system. Additionally, we discovered that the smallest particle mimics the role of the ferrofluid, by shifting the locations in phase space where the bidisperse crystal structures can be experimentally obtained. Finally, we demonstrate that 3-particle crystal structures can be tuned by varying the strength of the external field, which is not possible in a 2-particle system.

Initiated chemical vapor deposition-based method for patterning polymer and metal microstructures on curved substrates

A simple, efficient, and scalable method for patterning microstructures on curved substrates is demonstrated. Initiated chemical vapor deposition is used to synthesize a thin film that crosslinks upon UV exposure. Polymeric features are defined on glass rods with high curvature and used as masks for metal patterning. Additionally, vapor-deposited polymer layers are selectively patterned to produce bifunctional surfaces.

Zipping effect on omniphobic surfaces for controlled deposition of minute amounts of fluid or colloids

When a drop sits on a highly liquid-repellent surface (super-hydrophobic or super-omniphobic) made of periodic micrometer-sized posts, its contact-line can recede with very weak mechanical retention providing that the liquid stays on top of the microsized posts. Occurring in both sliding and evaporation processes, the achievement of low-contact-angle hysteresis (low retention) is required for discrete microfluidic applications involving liquid motion or self-cleaning; however, careful examination shows that during receding, a minute amount of liquid is left on top of the posts lying at the receding edge of the drop. For the first time, the heterogeneities of these deposits along the drop-receding contact-line are underlined. Both nonvolatile liquid and particle-laden water are used to quantitatively characterize what rules the volume distribution of deposited liquid. The experiments suggest that the dynamics of the liquid de-pinning cascade is likely to select the volume left on a specific post, involving the pinch-off and detachment of a liquid bridge. In an applied prospective, this phenomenon dismisses such surfaces for self-cleaning purposes, but offers an original way to deposit controlled amounts of liquid and (bio)-particles at well-targeted locations.

Designer hydrophilic regions regulate droplet shape for controlled surface patterning and 3D microgel synthesis

A simple technique is presented for controlling the shapes of micro- and nanodrops by patterning surfaces with special hydrophilic regions surrounded by hydrophobic boundaries. Finite element method simulations link the shape of the hydrophilic regions to that of the droplets. Shaped droplets are used to controllably pattern planar surfaces and microwell arrays with microparticles and cells at the micro- and macroscales. Droplets containing suspended sedimenting particles, initially at uniform concentration, deposit more particles under deeper regions than under shallow regions. The resulting surface concentration is thus proportional to the local fluid depth and agrees well with the measured and simulated droplet profiles. A second application is also highlighted in which shaped droplets of prepolymer solution are crosslinked to synthesize microgels with tailored 3D geometry.

Recent progress on surface pattern fabrications based on monolayer colloidal crystal templates and related applications

This review summarizes the recent progress toward the fabrication of surface patterns depending on the monolayer colloidal crystal templates. Based on the structural differences of the acquired surface patterns, various synthesis routes are introduced in detail. The diverse device applications of the synthesized surface patterns are also summarized, including sensors, energy-related devices, field emissions, wettability control, and so on. Future research should focus on surface patterns composed of multiple-layered structures and hybrid materials, and the widening of their application explorations.

Large-area protein patterns generated by ordered binary colloidal assemblies as templates

We demonstrate the use of binary colloidal assemblies as lithographic masks to generate tunable Au patterns on SiO(2) substrates with dimensions ranging from micrometers to nanometers. Such patterns can be modified with different chemistries to create patterns with well-defined sites for selective adsorption of proteins, where the pattern size and spacing is adjustable depending on particle choice. In our system, the binary colloidal assemblies contain large and small particles of similar or different material and are self-assembled from dilute dispersions with particle size ratios ranging from 0.10 to 0.50. This allows masks with variable morphology and thus production of chemical patterns of tunable geometry. Finally, the Au or SiO(2) regions of the pattern are surface modified with protein resistant oligoethyleneglycol self-assembled molecules, which facilitates site selective adsorption of proteins into the unmodified regions of the pattern. This we show with fluorescently labeled bovine serum albumin.