Applications such as biosensing,
plasmonics, and nanoelectronics
require nanoscale metal structures with controlled dimensions and
placement. However, significant challenges remain in the fabrication
of metal nanostructures of controlled size, shape, and placement on
a solid support. Among these challenges are precise positional control
at the nanoscale, flexibility and tunability in shape, and the cost
and complexity of methods. This work presents the development and
exploration of methods for the fabrication of copper, silver, and
gold (Cu, Ag, and Au) nanostructures directly on silicon (Si) substrates
through the use of atomic force microscopy (AFM)-based nanofabrication
using a self-assembled monolayer (SAM) resist followed by metal deposition
in the structure using electroless deposition (ELD). The importance
of the role of the SAM resist layer is highlighted, as it is critical
to prevent metal deposition on the areas of the substrate outside
the desired pattern. We have found that octadecyltrichlorosilane (OTS)
monolayers are much more robust and resistant films for the ELD process
than either octadecyl SAMs, formed from alkenes on hydrogen-terminated
Si, or octadecyldimethylchlorosilane (ODMS) SAM films. In addition,
the patterning parameters used for the AFM-based fabrication, the
ELD solution parameters, and the role of doping of Si have been explored
and together the results suggest that with proper tuning of the ELD
solution concentrations and the use of a robust SAM resist film, such
as OTS, tunable metal nanostructures are achievable. This is demonstrated
here for Cu, Ag, and Au, but the process should be adaptable to a
variety of metals, as long as the redox potentials are compatible
with the oxidation of Si. Importantly, this method exploits the exquisite
tunability of AFM-based lithography to provide precise control over
the size, shape, and position of the metal nanostructure. This provides
significant advantages for prototyping of new structures, as well
as fundamental investigations of the properties of such nanostructures.