We report the formulation of siloxane polymers for high-resolution, high-accuracy stamps for soft lithography. With this technique, a molecular, polymeric, or liquid ink is applied to the surface of a stamp and then transferred by conformal contact to a substrate. Stamps for this technique are usually made of a commercial siloxane elastomer with appropriate mechanical properties to achieve conformal contact but are incapable of printing accurate, submicrometer patterns. To formulate better stamp polymers, we used models of rubber-like elasticity as guidelines. Poly(dimethylsiloxane) networks were prepared from vinyl and hydrosilane end-linked polymers and vinyl and hydrosilane copolymers, with varying mass between cross-links and junction functionality. The polymer formulations were characterized by strain at break as well as compression modulus and surface hardness measurements. This resulted in the identification of bimodal polymer networks having mechanical properties that allow the replication of high-density patterns at the 100 nm scale and that withstand the mechanical constraints during use as a stamp material. We also demonstrate advantageous implementations of the formulated polymers in hybrid stamps that achieve submicrometer-dimensional accuracy over large areas.

Bulk syntheses of colloids efficiently produce nanoparticles with unique and useful properties. Their integration onto surfaces is a prerequisite for exploiting these properties in practice. Ideally, the integration would be compatible with a variety of surfaces and particles, while also enabling the fabrication of large areas and arbitrarily high-accuracy patterns. Whereas printing routinely meets these demands at larger length scales, we have developed a novel printing process that enables positioning of sub-100-nm particles individually with high placement accuracy. A colloidal suspension is inked directly onto printing plates, whose wetting properties and geometry ensure that the nanoparticles only fill predefined topographical features. The dry particle assembly is subsequently printed from the plate onto plain substrates through tailored adhesion. We demonstrate that the process can create a variety of particle arrangements including lines, arrays and bitmaps, while preserving the catalytic and optical activity of the individual nanoparticles.

Microfluidic networks (microFNs) were used to pattern biomolecules with high resolution on a variety of substrates (gold, glass, or polystyrene). Elastomeric microFNs localized chemical reactions between the biomolecules and the surface, requiring only microliters of reagent to cover square millimeter-sized areas. The networks were designed to ensure stability and filling of the microFN and allowed a homogeneous distribution and robust attachment of material to the substrate along the conduits in the microFN. Immunoglobulins patterned on substrates by means of microFNs remained strictly confined to areas enclosed by the network with submicron resolution and were viable for subsequent use in assays. The approach is simple and general enough to suggest a practical way to incorporate biological material on technological substrates.

A wide variety of methods are now available for the synthesis of colloidal particle having controlled shapes, structures, and dimensions. One of the main challenges in the development of devices that utilize micro- and nanoparticles is still particle placement and integration on surfaces. Required are engineering approaches to control the assembly of these building blocks at accurate positions and at high yield. Here, we investigate two complementary methods to create particle assemblies ranging from full layers to sparse arrays of single particles starting from colloidal suspensions of gold and polystyrene particles. Convective assembly was performed on hydrophilic substrates to create crystalline mono- or multilayers using the convective flow of nanoparticles induced by the evaporation of solvent at the three-phase contact line of a solution. On hydrophobic surfaces, capillary assembly was investigated to create sparse arrays and complex three-dimensional structures using capillary forces to trap and organize particles in the recessed regions of a template. In both methods, the hydrodynamic drag exerted on the particle in the suspension plays a key role in the assembly process. We demonstrate for the first time that the velocity and direction of particles in the suspension can be controlled to perform assembly or disassembly of particles. This is achieved by setting the temperature of the colloidal suspension above or below the dew point. The influence of other parameters, such as substrate velocity, wetting properties, and pattern geometry, is also investigated. For the particular case of capillary assembly, we propose a mechanism that takes into account the relative influences of these parameters on the motion of particles and that describes the influence of temperature on the assembly efficiency.