Dewetting-mediated pattern formation inside the coffee ring

Evaporative self-assembly in colloidal droplets: Emergence of ordered structures from complex fluids

Colloidal droplet evaporation is an intriguing and intricate phenomenon that has captured the interest of scientists across diverse disciplines, including physical chemistry, fluid dynamics, and soft matter science, over the past two decades. Despite being a non-equilibrium system with inherent challenges posed by coffee ring formation and Marangoni effects, which hinder the precise control of deposition patterns, evaporative self-assembly presents a convenient and cost-effective approach for generating arrays of well-ordered structures and functional patterns with wide-ranging applications in inkjet printing, photonic crystals, and biochemical assays. In the realm of printed electronics and photonics, effectively mitigating coffee rings while achieving uniformity and orderliness has emerged as a critical factor in realising the next generation of large-area, low-cost, flexible devices that are exceptionally sensitive and high-performance. This review highlights the evaporative self-assembly process in colloidal droplets with a focus on the intricate mechanical environment, self-assembly at diverse interfaces, and potential applications of these assembling ordered structures.

Diffusiophoresis-enhanced particle deposition for additive manufacturing

The ability to govern particle assembly in an evaporative-driven additive manufacturing (AM) can realize multi-scale features fundamental to creating printed electronics. However, existing techniques remain challenging and often require templates or contaminating solutes. We explore the control of particle deposition in 3D-printed colloids by diffusiophoresis, a previously unexplored mechanism in multi-scale AM. Diffusiophoresis can introduce spontaneous phoretic particle motion by establishing local solute concentration gradients. We show that diffusiophoresis can play a dominant role in complex evaporative-driven particle assembly, enabling a fundamentally new and versatile control of particle deposition in a multi-scale AM process.

An Efficiently Doped PEDOT:PSS Ink Formulation via Metastable Liquid-Liquid Contact for Capillary Flow-Driven, Hierarchically and Highly Conductive Films

With commercial electronics transitioning toward flexible devices, there is a growing demand for high-performance polymers such as poly(3,4-ethylenedioxythiophene): poly(styrene sulfonate) (PEDOT:PSS). Previous breakthroughs in promoting the conductivity of PEDOT:PSS, which mainly stem from solvent-treatment and transfer-printing strategies, remain as inevitable challenges due to the inefficient, unstable, and biologically incompatible process. Herein, a scalable fabrication of conducting PEDOT:PSS inks is reported via a metastable liquid-liquid contact (MLLC) method, realizing phase separation and removal of excess PSS simultaneously. MLLC-doped inks are further used to prepare ring-like films through a compromise between the coffee-ring effect and the Marangoni vortex during evaporation of droplets. The specific control over deposition conditions allows for tunable ring-like morphologies and preferentially interconnected networks of PEDOT:PSS nanofibrils, resulting in a high electrical conductivity of 6,616 S cm^-1 and excellent optical transparency of the film. The combination of excellent electrical properties and the special morphology enables it to serve as electrodes for touch sensors with gradient pressure sensitivity. These findings not only provide new insight into developing a simple and efficient doping method for commercial PEDOT:PSS ink, but also offer a promising self-assembled deposition pattern of organic semiconductor films, expanding the applications in flexible electronics, bioelectronics as well as photovoltaic devices.

Evaporative Deposition of Surfactant-Laden Nanofluid Droplets over a Silicon Surface

Morphologies of evaporative deposition, which has been widely applied in potential fields, were induced by the competition between internal flows inside evaporating droplets. Controlling the pattern of deposition and suppressing the coffee-ring effect are essential issues of intense interest in the aspects of industrial technologies and scientific applications. Here, evaporative deposition of surfactant-laden nanofluid droplets over silicon was experimentally investigated. A ring-like deposition was formed after complete evaporation of sodium dodecyl sulfate (SDS)-laden nanofluid droplets with an initial SDS concentration ranging from 0 to 1.5 CMC. In the case of initial SDS concentrations above 1.3 CMC, no cracks were observed in the ring-like deposition, indicating that the deposition patterns of nanofluid droplets could be completely changed and cracks could be eliminated by sufficient addition of SDS. With the increase of the initial concentration of hexadecyl trimethylammonium bromide (CTAB), the width of the deposition ring gradually decreased until no ring-like structure was formed. On the contrary, with the increase of the initial Triton X-100 (TX-100) concentration, the width of the deposition ring gradually increased until a uniform deposition was generated. Moreover, when the initial TX-100 concentration was high, a "tree-ring-like" pattern was discovered. Besides, morphologies of evaporative pattern due to the addition of surfacants were qualitatively analyzed.

Colloidal Deposits via Capillary Bridge Evaporation and Particle Sorting Thereof

Evaporating droplets of colloidal suspensions leave behind particle deposits which could be effectively controlled via manipulating the surrounding conditions and particles and liquid properties. While previous studies extensively focused on sessile and pendant droplets, the present work investigates the evaporation dynamics of capillary bridges of colloidal suspensions formed between two parallel plates. We vary the wettability of the plates and the particle size and composition of the colloidal suspensions, keeping the same spacing between the plates. We employ side visualization, optical microscopy, fluorescence microscopy, and scanning electron microscopy and develop computational and theoretical models to collect the data. A computational model based on diffusion-limited evaporation is used to characterize the timescale of the evaporation of the capillary bridge. The model predictions are in good agreement with the present and prior experimental measurements. We discuss about the deposits of monodispersed particle suspension formed by the interplay of pinning of the contact line and evaporation dynamics. Multiple rings on the plates are observed due to the stick-slip motion of the contact line. The larger particles tend to form asymmetric deposits, with most particles concentrated on the bottom plates due to a considerably stronger gravitational pull than the hydrodynamic drag. This deposition is explained by estimating the competing forces on the particles during the evaporation. A regime map is proposed for classifying deposits on the particle size wettability plane. Lastly, we demonstrate size-based particle sorting of bidispersed colloidal suspensions in this framework. We describe two mechanisms: gravity-assisted and geometry-assisted sorting, which can be designed to sort particles efficiently. A regime map depicting the regions of influence of each mechanism is presented.

Colloidal monolayers with cell-like tessellations via interface assisted evaporative assembly

HYPOTHESIS

Evaporating sessile drops containing surface active colloids is a promising route to self-assemble two-dimensional nanostructures. The standard protocol is to first self-assemble surface active nanoscale particles at the water-vapour interface and subsequently transfer it on to a solid surface. Colloidal monolayers with very few morphologies have been fabricated, exploiting this bottom-up self-assembly technique. However, the evaporation kinetics under controlled humidity conditions may dramatically alter the microstructure of self-assembled colloidal monolayers at the liquid-vapor interface and that on the solid surfaces, an aspect that has not been fully addressed in the prior studies.

EXPERIMENTS

To this end, we present an experimental study of evaporation driven self-assembly of soft poly(N-isopropylacrylamide) (pNIPAM) microgel particles loaded in a sessile drop. The surface-active microgel particles spontaneously populate the water-vapour interface facilitating the suppression of the coffee-ring effect and the formation of monolayer stains. The role of evaporation kinetics under controlled humidity conditions on the colloid's microstructure adsorbed to the solvent-air interface and on the morphology of the colloidal monolayer transferred onto the solid surface are studied in detail.

FINDINGS

The formation of particle-free and particle-rich regions at the water-vapor interface is observed for sessile drops evaporated under saturated humidity conditions. We show that the evaporation induced shrinkage of the interface area and the enhancement of the areal density of microgel particles adsorbed onto the interface leads to a restructuring of the particle-laden interface. The rearrangement of microgel particles along the water-vapor interface resembling the de-wetting assisted patterns is transferred to the solid substrate upon complete evaporation of the solvent. The microgel particles in the deposit assemble into domains with enhanced crystalline order. The evolution of Voronoi entropy across the monolayer deposit patterns obtained by the standard and slow evaporation routes are presented.

Applying droplets and films in evaporative lithography

This review covers experimental results of evaporative lithography and analyzes existing mathematical models of this method. Evaporating droplets and films are used in different fields, such as cooling of heated surfaces of electronic devices, diagnostics in health care, creation of transparent conductive coatings on flexible substrates, and surface patterning. A method called evaporative lithography emerged after the connection between the coffee ring effect taking place in drying colloidal droplets and naturally occurring inhomogeneous vapor flux densities from liquid-vapor interfaces was established. Essential control of the colloidal particle deposit patterns is achieved in this method by producing ambient conditions that induce a nonuniform evaporation profile from the colloidal liquid surface. Evaporative lithography is part of a wider field known as "evaporative-induced self-assembly" (EISA). EISA involves methods based on contact line processes, methods employing particle interaction effects, and evaporative lithography. As a rule, evaporative lithography is a flexible and single-stage process with such advantages as simplicity, low price, and the possibility of application to almost any substrate without pretreatment. Since there is no mechanical impact on the template in evaporative lithography, the template integrity is preserved in the process. The method is also useful for creating materials with localized functions, such as slipperiness and self-healing. For these reasons, evaporative lithography attracts increasing attention and has a number of noticeable achievements at present. We also analyze limitations of the approach and ways of its further development.

Absorption induced ordered ring and inner network structures on a nanoporous substrate

Interaction of colloidal droplets with a porous medium is the key issue for many industrial applications, such as direct-ink-write printing on flexible wearable clothing. In this work, we find a novel pattern of an ordered ring with inner network from a colloidal droplet resting on the nanoporous substrate. Experimental results show that the outward flow caused by the lateral absorption is responsible for the ring structures. The mutual competition between the inward dewetting and the outward flow determines the formation of the inner network pattern. The capillary immersion forces dominate the self-assembly of particles and promote the ordered arrays of the structures.

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.

Joint effect of advection, diffusion, and capillary attraction on the spatial structure of particle depositions from evaporating droplets

A simplified model is developed, which allows us to perform computer simulations of the particles transport in an evaporating droplet with a contact line pinned to a hydrophilic substrate. The model accounts for advection in the droplet, diffusion, and particle attraction by capillary forces. On the basis of the simulations, we analyze the physical mechanisms of forming of individual chains of particles inside the annular sediment. The parameters chosen correspond to the experiments of Park and Moon [Langmuir 22, 3506 (2006)LANGD50743-746310.1021/la053450j], where an annular deposition and snakelike chains of colloid particles have been identified. The annular sediment is formed by advection and diffusion transport. We find that the close packing of the particles in the sediment is possible if the evaporation time exceeds the characteristic time of diffusion-based ordering. We show that the chains are formed by the end of the evaporation process due to capillary attraction of particles in the region bounded by a fixing radius, where the local droplet height is comparable to the particle size. At the beginning of the evaporation, the annular deposition is shown to expand faster than the fixing radius moves. However, by the end of the process, the fixing radius rapidly outreaches the expanding inner front of the ring. The snakelike chains are formed at this final stage when the fixing radius moves toward the symmetry axis.

Evaporative Crystallization of Spirals

Spiral motifs are pervasive in nature, art, and technology due to their functional property of providing compact length. Nature is particularly adept at spiral patterning, and yet, the spirals observed in seashells, hurricanes, rams' horns, flower petals, etc. all evolve via disparate physical mechanisms. Here, we present a mechanism for the self-guided formation of spirals from evaporating saline drops via a coupling of crystallization and contact line dynamics. These patterns are in contrast to commonly observed patterns from evaporation of colloidal drops, which are discrete (rings, concentric rings) or continuous (clumps, uniform deposits) depending on the particle shape, contact line dynamics, and evaporation rate. Unlike the typical process of drop evaporation where the contact line moves radially inward, here, a thin film pinned by a ring of crystals ruptures radially outward. This motion is accompanied by a nonuniform pinning of the contact line due to crystallization, which generates a continuous propagation of pinning and depinning events to form a spiral. By comparing the relevant timescales of evaporation and diffusion, we show that a single dimensionless number can predict the occurrence of these patterns. These insights on self-guided crystallization of spirals could be used to create compact length templates.

Pattern Formation in Drying Sessile and Pendant Droplet: Interactions of Gravity Settling, Interface Shrinkage, and Capillary Flow

We reported the interactions of the gravitational sedimentation, interface shrinkage, and outward capillary flow in drying droplets. This coupling effect is the inference we draw from deposition patterns of both sessile and pendant droplets, which contain particles of different sizes, evaporating on a patterned substrate. The deposition difference between sessile and pendant droplets containing microparticles indicated that gravitational sedimentation has a significant influence on the deposition morphology. The phase diagram shows that the particle deposition process can be divided into two stages: in the first stage, the competition between the interface shrinkage and the gravitational sedimentation determines whether the particles can be captured by the liquid-air interface; in the second stage, the capillary flow takes the particles inside the droplet toward the edge. The deposition morphology is the result of competition and cooperation interactions of the free setting, interface shrinkage, and outward capillary flow.

Evaporation and morphological patterns of bi-dispersed colloidal droplets on hydrophilic and hydrophobic surfaces

Understanding the formation of different morphological patterns depending on the particle size and surface wettability has great relevance in the separation, mixing and concentration of micro/nano particles and biological entities. We report the evaporation and morphological patterns of evaporating bi-dispersed colloidal droplets on hydrophilic and hydrophobic surfaces. To explain the underlying mechanisms of various particle distribution patterns, we propose a phenomenological model that accounts for the drag force, van der Waals and electrostatic interaction forces, and surface tension force acting on the particles. In the case of the hydrophilic surface (θ ∼ 27°), there is a competition between the frictional force arising due to the van der Waals (∼10-8 N) and electrostatic interaction forces (∼10-10 N) and the surface tension force (∼10-7 N) that depends on the particle size. Consequently, the smaller particles (0.2 and 1.0 μm in diameter) are found to be pinned and form an outer ring at the contact line whereas the larger particles (3.0 and 6.0 μm in diameter) move inward, either forming an inner ring or flocculating depending on the particle size. Interestingly, a completely different morphological pattern of the micro/nano particles is observed on a hydrophobic substrate (θ ∼ 110°): contact line pinning is no longer observed and particles form a centralized deposition pattern. The order of the magnitude of the surface tension force is higher as compared to the frictional force (∼10-8 N); thus the particles are driven radially inward and accumulate at the center of the droplet. Owing to the mixed mode of evaporation toward the end of evaporation, only a fraction of smaller particles travel radially outward due to the coffee-ring effect. Scanning electron microscopy images reveal that smaller particles are present mostly at the center with a small fraction of smaller particles at the edge of the pattern, whereas larger particles are uniformly distributed throughout.

Rupture of ultrathin solution films on planar solid substrates induced by solute crystallization

On-line optical imaging of continuously thinning planar films in a spin cast configuration reveals the rupture behavior of ultra-thin films of binary mixtures of a volatile solvent and a nonvolatile solute. The pure solvents completely wet the silica substrates whereas the solution films rupture at certain film thicknesses, h_rupture, which depend on, c₀, the initial weighing in solute concentrations. With small c₀, h_rupture increases proportional to c₀. With high c₀, all films rupture at h_rupture≈50nm, independent of c₀. The findings can be explained by the solute enrichment during the evaporative thinning. Solute crystallization at the liquid/substrate interface upon reaching solute supersaturation leads to locally different wetting properties. This induces locally the rupture of the film as soon as it is sufficiently thin. A proper data rescaling based on this scenario yields a universal rupture behavior of various different solvent/solute mixtures.

Microstructure Formation of Functional Polymers by Evaporative Self-Assembly under Flexible Geometric Confinement

Polymer microstructures are widely used in optics, flexible electronics, and so forth. We demonstrate a cost-effective bottom-up manner for patterning polymer microstructures by evaporative self-assembly under a flexible geometric confinement at a high temperature. Two-parallel-plates confinement would become curve-to-flat shape geometric confinement as the polydimethylsiloxane (PDMS) cover plate deformed during solvent swelling. We found that a flexible cover plate would be favorable for the formation of gradient microstructures, with various periodicities and widths obtained at varied heights of clearance. After thermal annealing, the edge of the PMMA (Poly-methylmethacrylate) microstructures would become smooth, while the RR-P3HT (regioregular-poly(3-hexylthiophene)) might generate nanocrystals. The morphologies of RR-P3HT structures included thick films, straight lines, hierarchical stripes, incomplete stripes, and regular dots. Finally, a simple field-effect transistor (FET) device was demonstrated with the RR-P3HT micropattern as an active layer.