High-Resolution Roll-to-Roll Additive Patterning of Functional Materials on Large Areas via Topographic Discontinuous...

Area of Science:

• Materials Science and Engineering
• Nanotechnology
• Additive Manufacturing

Background:

• Two-dimensional (2D) nanoscale functional materials are critical for advanced optics, photonics, optoelectronics, and sensors.
• Conventional fabrication methods face limitations in energy consumption, waste generation, and scalability.

Purpose of the Study:

• To introduce a sustainable and scalable roll-to-roll (R2R) additive nanopatterning process for large-area, high-resolution 2D metamaterial production.
• To demonstrate the utility of UV-curable Norland Optical Adhesive (NOA) and its thermally switchable wetting properties in this process.

Main Methods:

• Utilized a combination of UV-based R2R nanoimprinting and topographical discontinuous dewetting (TDD).
• Leveraged the transition of NOA from high to low surface energy states upon annealing to guide ink deposition.
• Employed an additive approach to minimize material consumption.

Main Results:

• Achieved nanopatterning with feature sizes down to tens of nanometers over large areas.
• Demonstrated selective ink deposition into recessed areas of annealed NOA, with dewetting on elevated surfaces.
• Showcased significantly reduced ink consumption (approx. 100 nL for 10 cm²) due to the additive nature.

Conclusions:

• The developed R2R additive nanopatterning technique offers an eco-friendly and scalable solution for fabricating nanoscale functional materials.
• This method supports diverse materials (metals, semiconductors, dielectrics) and enables control over pattern thickness and multilayer structures.
• The process facilitates advancements in metamaterials, optoelectronics, and sensor systems through efficient, large-area production.