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Microsphere Photolithography (MPL) is a nanopatterning technique that utilizes a self-assembled monolayer of microspheres as an optical element to focus incident radiation inside a layer of photoresist. The microspheres produces a sub-diffraction limited photonic-jet on the opposite side of each microsphere from the illumination. When combined with pattern transfer techniques such as etching/lift-off, MPL provides a versatile, low-cost fabrication method for producing hexagonal close-packed metasurfaces. This article investigates the MPL process for creating refractive index (RI) sensors on the cleaved tips of optical fiber. The resonant wavelength of metal elements on the surface is dependent on the local dielectric environment and allows the refractive index of an analyte to be resolved spectrally. A numerical study of hole arrays defined in metal films shows that the waveguide mode provides good sensitivity to the analyte refractive index. This can be readily tuned by adjusting the MPL exposure and the simulation results guide the fabrication of a defect tolerant refractive index sensor on the tip of a fiber tip with a sensitivity of 613 nm/RIU. The conformal nature of the microsphere monolayer simplifies the fabrication process and provides a viable alternative to direct-write techniques such as Focused Ion Beam (FIB) milling 

Atmospheric condensation is very important for multiple practical applications such as heat transfer, thermal management, aerospace, and condensate harvesting. Water droplets heterogeneously nucleate on the surfaces when the temperature is below the dew point temperature. The nucleation energy barrier for a condensed droplet varies significantly with the humidity content in the operating environment. The freezing of this condensate is also dependent on the operating conditions and surface properties. This article presents an experimental study of condensation and freezing from humid air with the objective of understanding how the surface morphology and chemistry determines the droplet shape and wetting state. Hexagonal close-packed arrays of titanium (Ti) pillars are patterned using microsphere photolithography (MPL). The Ti nanostructured surface was tested with and without a Teflon© coating to reveal the condensate harvesting, passive freezing, and dropwise condensation applications, respectively. Condensation and freezing tests were conducted in the presence of non-condensable gases (air) with different relative humidity (RH) levels to control the nucleation site density. The experiments showed that droplet growth occurs in the following stages: initial nucleation, direct growth, and coalescence events. By pinning droplets, coalescence is suppressed for the Ti nanopillared surface altering the size distribution of droplets and significantly accelerating the freezing process.