With the development of nanomaterial-based nanodevices, it became inevitable to develop cost-effective and simple nanofabrication technologies enabling the formation of nanomaterial assembly in a controllable manner. Herein, we present suspended monolithic carbon single nanowires and nanomeshes bridging two bulk carbon posts, fabricated in a designed manner using two successive UV exposure steps and a single pyrolysis step. The pyrolysis step is accompanied with a significant volume reduction, resulting in the shrinkage of micro-sized photoresist structures into nanoscale carbon structures. Even with the significant elongation of the suspended carbon nanowire induced by the volume reduction of the bulk carbon posts, the resultant tensional stress along the nanowire is not significant but grows along the wire thickness; this tensional stress gradient and the bent supports of the bridge-like carbon nanowire enhance structural robustness and alleviate the stiction problem that suspended nanostructures frequently experience. The feasibility of the suspended carbon nanostructures as a sensor platform was demonstrated by testing its electrochemical behavior, conductivity-temperature relationship, and hydrogen gas sensing capability.

Redox cycling is a commonly used electrochemical sensing scheme for enhancing faradaic current signals. This effect can be improved by either optimizing electrode geometries or restricting electrochemical reactions within a limited volume. Here, we demonstrate a simple batch fabrication of 1 : 1 aspect ratio carbon interdigitated array nanoelectrodes integrated in a polydimethylsiloxane microchannel that enables current amplification by up to 1116 times. We also examine the factors that influence the effect of redox cycling, including the electrode aspect ratio and channel height, by using experiments and simulations.

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