Controlled filamentation instability as a scalable fabrication approach to flexible metamaterials

Long and flexible arrays of nanowires find impactful applications in sensing, photonics, and energy harvesting. Conventional manufacturing relies largely on lithographic methods limited in wafer size, rigidity, and machine write time. Here, we report a scalable process to generate encapsulated flexible nanowire arrays with high aspect ratios and excellent tunable size and periodicity. Our strategy is to control nanowire self-assembly into 2D and 3D architectures via the filamentation of a textured thin film under anisotropic stretching. This is achieved by coupling soft lithography, glancing angle deposition, and thermal drawing to obtain well-ordered meters-long nanowires with diameters down to 50 nanometers. We demonstrate that the nanowire diameter and period of the array can be decoupled and manipulated independently. We propose a filamentation criterion and perform numerical simulations implementing destabilizing long-range Van der Waals interactions. Applied to high-index chalcogenide glasses, we show that this decoupling allows for tuning diffraction. Finally, harnessing Mie resonance, we demonstrate the possibility of manufacturing macroscopic meta-grating superstructures for nanophotonic applications.