Ordered non-close packed colloidal array with morphology control

Non-close packed (NCP) colloidal arrays find wide applications in the fields of photonics, optical chip fabrication, nano sphere lithography and so on. However, unlike their close packed counterparts, such arrays cannot be obtained by direct self-organization of colloidal particles and require specialized techniques involving plasma/reactive ion etching, electric field driven assembly, substrate stretching or precise positioning of the particles. In this article, we present a facile template guided approach for fabricating ordered NCP arrays of colloidal particles. First, we employ soft lithography to replicate self-assembled hexagonal close packed (HCP) arrays of 'larger colloidal particles' (LPs) to obtain a topographically patterned positive and/or negative replica of the initial array. These replicas are then used as templates to spin coat 'smaller colloidal particles' (SPs), which may even have some degree of poly-dispersity, to obtain ordered NCP arrays. We further show that pattern morphology can be modulated based on whether a single or a double replicated template is used to confine the SPs, the concentration (C_n) of the SPs in the casting solution as well as the relative commensuration of the diameter of the SPs (d_s) with that of the LPs (d_L). Finally, we show that such NCP arrays can be transferred onto any flat surface by UVO mediated colloidal transfer printing.