Many of the applications proposed for nanowires and carbon nanotubes require these components to be organized over large areas with controlled orientation and density. Although progress has been made with directed assembly and LangmuirBlodgett approaches, it is unclear whether these techniques can be scaled to large wafers and non-rigid substrates. Here, we describe a general and scalable approach for large-area, uniformly aligned and controlled-density nanowire and nanotube films, which involves expanding a bubble from a homogeneous suspension of these materials. The blown-bubble films were transferred to single-crystal wafers of at least 200 mm in diameter, flexible plastics sheets of dimensions of at least 225 3 300 mm 2 and highly curved surfaces, and were also suspended across open frames. In addition, electrical measurements show that large arrays of nanowire field-effect transistors can be efficiently fabricated on the wafer scale. Given the potential of blown film extrusion to produce continuous films with widths exceeding 1 m, we believe that our approach could allow the unique properties of nanowires and nanotubes to be exploited in applications requiring large areas and relatively modest device densities.Semiconductor nanowires (NWs) and carbon nanotubes (NTs) exhibit physical properties that make them attractive building blocks for many electronic and optical applications [1][2][3] . To realize such applications, researchers have directed considerable effort to the development of methods of assembly that might ultimately lead to integrated systems. For example, there have been studies of individual or small numbers of NW and NT devices prepared by random deposition, electric field directed assembly 4 , flowassisted alignment 5 , and selective chemical and biological patterning 6,7 , and up to centimetre-scale assembly of NWs using the Langmuir-Blodgett technique 8 . However, it is still unclear whether these methods can be extended to large-scale assembly of NWs and NTs on both rigid and flexible substrates with controlled alignment and density.Blown film extrusion is a well-developed process for the manufacture of plastic films in large quantities, which involves extruding a molten polymer and inflating it to obtain a balloon, which can be collapsed and slit to form continuous flat films with widths exceeding 1 m at rates in the order of 500 kg h 21 (refs. 9 -11). We have applied this basic idea for the first time to the formation of nanocomposite films where the density and orientation of the NWs and NTs are controlled within the film. The basic steps in our approach (Fig. 1a) consist of (i) preparation of a homogeneous, stable and controlled concentration polymer suspension of NWs or NTs, (ii) expansion of the polymer suspension using a circular die to form a bubble at controlled pressure, P, and expansion rate, where stable vertical expansion is achieved using an external vertical force, F, and (iii) transfer of the bubble film to substrates or open frame structures.
BLOWN BUBBLE FILMSTo characte...