Road to Practical Manufacturing of Nanopattern-Scaffolded Functional Devices: From Scalable Mechanical Nanopatterning...

Patterned micro- and nanostructures can provide versatile active scaffolds for functional devices, often integrating complementary materials, by regulating their arrangements, interfaces, transport pathways, and physicochemical properties. Nanopattern-scaffolded functional devices, increasingly pursued in that regard, require a practical manufacturing route that combines large-area micro- and nanopatterning with facile integration with functional materials. This review summarizes our studies progressing along such a road in sequence of three platform technologies (PTs), from scalable mechanical patterning (PT-I) through solution-processable functional surface architecturing (PT-II) to device integration with multidimensional nanostructures (PT-III). PT-I presents scalable mechanical nanopatterning technologies, beginning with large-area nanoimprinting by developing a large-area-tiled mold and then involving continuous mechanical patterning methods inspired by classic machining principles, including indentation, extrusion, and scribing. PT-II addresses the low-temperature solution-processable architecturing of diverse carbon- and metal-nanostructured functional surfaces, specifically by utilizing ionic metal inks and carbon-nanotube coatings. PT-III demonstrates several strategies for nanopattern-scaffolded integration of functional devices incorporating multidimensional nanomaterials, including solution-processable, metal-nanopattern-directed semiconductor nanowire growth, and nanowire-interconnected metal-wire-patterned electrode and micrograting sidewall-scaffolded structure. The methods, principles, and ideas presented in this review share and head to a common goal: practical manufacturing of nanostructure-functionalized devices with minimal reliance upon optical lithography, vacuum processing, and chemical etching.