skip to main content


Title: Room‐Temperature Annealing‐Free Gold Printing via Anion‐Assisted Photochemical Deposition
Abstract

Metal patterning via additive manufacturing has been phasing‐in to broad applications in many medical, electronics, aerospace, and automotive industries. While previous efforts have produced various promising metal‐patterning strategies, their complexity and high cost have limited their practical application in rapid production and prototyping. Herein, a one‐step gold printing technique based on anion‐assisted photochemical deposition (APD), which can directly print highly conductive gold patterns (1.08 × 107S m−1) under ambient conditions without post‐annealing treatment, is introduced. Uniquely, the APD uses specific ion effects with projection lithography to pattern Au nanoparticles and simultaneously sinter them into tunable porous gold structures. The significant influence of kosmotropic or chaotropic anions in the precursor ink on tuning the morphologies and conductivities of the printed patterns by employing a series of different ions, including Clions, in the printing process is presented. Additionally, the resistance stabilities and the electrochemical properties of the APD‐printed gold patterns are carefully investigated. The high conductivity and excellent conformability of the printed Au electrodes are demonstrated with reliable performance in electrophysiological signal delivery and acquisition for biomedical applications. This work exploits the potential of photochemical‐deposition‐based metal patterning in flexible electronic manufacturing.

 
more » « less
NSF-PAR ID:
10369292
Author(s) / Creator(s):
 ;  ;  ;  ;  ;  ;  ;  ;  ;  
Publisher / Repository:
Wiley Blackwell (John Wiley & Sons)
Date Published:
Journal Name:
Advanced Materials
Volume:
34
Issue:
32
ISSN:
0935-9648
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. Abstract

    Structural color printings have broad applications due to their advantages of long-term sustainability, eco-friendly manufacturing, and ultra-high resolution. However, most of them require costly and time-consuming fabrication processes from nanolithography to vacuum deposition and etching. Here, we demonstrate a new color printing technology based on polymer-assisted photochemical metal deposition (PPD), a room temperature, ambient, and additive manufacturing process without requiring heating, vacuum deposition or etching. The PPD-printed silver films comprise densely aggregated silver nanoparticles filled with a small amount (estimated <20% volume) of polymers, producing a smooth surface (roughness 2.5 nm) even better than vacuum-deposited silver films (roughness 2.8 nm) at ~4 nm thickness. Further, the printed composite films have a much larger effective refractive indexn(~1.90) and a smaller extinction coefficientk(~0.92) than PVD ones in the visible wavelength range (400 to 800 nm), therefore modulating the surface reflection and the phase accumulation. The capability of PPD in printing both ultra-thin (~5 nm) composite films and highly reflective thicker film greatly benefit the design and construction of multilayered Fabry–Perot (FP) cavity structures to exhibit vivid and saturated colors. We demonstrated programmed printing of complex pictures of different color schemes at a high spatial resolution of ~6.5 μm by three-dimensionally modulating the top composite film geometries and dielectric spacer thicknesses (75 to 200 nm). Finally, PPD-based color picture printing is demonstrated on a wide range of substrates, including glass, PDMS, and plastic, proving its broad potential in future applications from security labeling to color displays.

     
    more » « less
  2. Nanoimprinting has been applied in many micro- and nanoscale engineered devices; applications include displays, organic electronics, photovoltaics, optical films, and optoelectronics; and in some cases, direct imprinting of functional polymeric devices. Applications in the photonics area can significantly relieve the stringent requirement needed for nanoelectronics. We provide examples of structural colors and optical meta-surfaces facilitated by nanoimprinting, as well as plasmonic lithography masks that can produce deep-subwavelength structures using ordinary UV light. Inkjet printing has been widely used in many applications, but still faces challenges in pattern precision and feature variations. Combining Nanoimprint for patterning and inkjet printing for material deposition will take the advantage of what both technologies can offer, and can provide a high precision additive manufacturing process. We will show printed photonic devices, e.g. electro-optic polymer based optical modulators. To extend nanoimprinting to solid materials other than polymeric films will require innovative and non-conventional approaches. One such process is Metal-assisted chemical (Mac) imprint, which combines MacEtch and nanoiprint and enables direct MacEtch of Si substrate using a hybrid imprinting mold having noble metal mask. However, only low aspect ratio structures have been obtained because of the mass-transport limitation in the previous molds. Recently we effectively solved this problem by a using a specially made mold of Pt-coated anodized aluminum oxide (AAO) membrane, where the holes through the entire thickness drastically enhances the mass-transport. As a result, very high aspect ratio Si nanowires were achieved by MacImprint. 
    more » « less
  3. Abstract

    Inkjet printing is rapidly emerging as a means to fabricate low‐cost electronic devices; however, its widespread adoption is hindered by the complexity of the inks and the relatively high processing temperatures, limiting it to only a few metals and substrates. A new approach for inkjet printing is described, based on commercially available, particle‐free inks formulated from inorganic metal salts and their subsequent low‐temperature conversion to metallic structures by a non‐equilibrium, inert gas plasma. This single, general method is demonstrated for a library of metals including gold (Au), silver (Ag), copper (Cu), palladium (Pd), platinum (Pt), lead (Pb), bismuth (Bi), and tin (Sn). As one figure of merit, the resistivities of the printed metals are measured to be between 2× and 10× of the respective bulk metals. Uniquely, it is found that the printed metal films exhibit a very large surface area because of the plasma‐initiated nucleation and growth process, making this technique attractive for sensing device applications. A Bi‐based trace Pb sensor, an Au‐based amyloid‐β42sensor, and an Au‐based strain gauge are fabricated as representative chemical, biological, and mechanical sensors, and are found to exhibit enhanced sensitivity compared to analogues made with conventional methods.

     
    more » « less
  4. Abstract

    As an alternative to traditional photolithography, printing processes are widely explored for the patterning of customizable devices. However, to date, the majority of high‐resolution printing processes for functional nanomaterials are additive in nature. To complement additive printing, there is a need for subtractive processes, where the printed ink results in material removal, rather than addition. In this study, a new subtractive patterning approach that uses electrohydrodynamic‐jet (e‐jet) printing of acid‐based inks to etch nanoscale zinc oxide (ZnO) thin films deposited using atomic layer deposition (ALD) is introduced. By tuning the printing parameters, the depth and linewidth of the subtracted features can be tuned, with a minimum linewidth of 11 µm and a tunable channel depth with ≈5 nm resolution. Furthermore, by tuning the ink composition, the volatility and viscosity of the ink can be adjusted, resulting in variable spreading and dissolution dynamics at the solution/film interface. In the future, acid‐based subtractive patterning using e‐jet printing can be used for rapid prototyping or customizable manufacturing of functional devices on a range of substrates with nanoscale precision.

     
    more » « less
  5. There has been an increasing need of technologies to manufacturing chemical and biological sensors for various applications ranging from environmental monitoring to human health monitoring. Currently, manufacturing of most chemical and biological sensors relies on a variety of standard microfabrication techniques, such as physical vapor deposition and photolithography, and materials such as metals and semiconductors. Though functional, they are hampered by high cost materials, rigid substrates, and limited surface area. Paper based sensors offer an intriguing alternative that is low cost, mechanically flexible, has the inherent ability to filter and separate analytes, and offers a high surface area, permeable framework advantageous to liquid and vapor sensing. However, a major drawback is that standard microfabrication techniques cannot be used in paper sensor fabrication. To fabricate sensors on paper, low temperature additive techniques must be used, which will require new manufacturing processes and advanced functional materials. In this work, we focus on using aerosol jet printing as a highresolution additive process for the deposition of ink materials to be used in paper-based sensors. This technique can use a wide variety of materials with different viscosities, including materials with high porosity and particles inherent to paper. One area of our efforts involves creating interdigitated microelectrodes on paper in a one-step process using commercially available silver nanoparticle and carbon black based conductive inks. Another area involves use of specialized filter papers as substrates, such as multi-layered fibrous membrane paper consisting of a poly(acrylonitrile) nanofibrous layer and a nonwoven poly(ethylene terephthalate) layer. The poly(acrylonitrile) nanofibrous layer are dense and smooth enough to allow for high resolution aerosol jet printing. With additively fabricated electrodes on the paper, molecularly-functionalized metal nanoparticles are deposited by molecularly-mediated assembling, drop casting, and printing (sensing and electrode materials), allowing full functionalization of the paper, and producing sensor devices with high surface area. These sensors, depending on the electrode configuration, are used for detection of chemical and biological species in vapor phase, such as water vapor and volatile organic compounds, making them applicable to human performance monitoring. These paper based sensors are shown to display an enhancement in sensitivity, as compared to control devices fabricated on non-porous polyimide substrates. These results have demonstrated the feasibility of paper-based printed devices towards manufacturing of a fully wearable, highly-sensitive, and wireless human performance monitor coupled to flexible electronics with the capability to communicate wirelessly to a smartphone or other electronics for data logging and analysis. 
    more » « less