We
report a novel one-step bottom-up fabrication method for multiscale-structured
black Si, which is characterized by randomly distributed microscale
Si layers covered with sub-100 nm protrusions with submicron boundary
grooves. The unique multiscale structure, suggested as a “nanocanyon,”
effectively minimizes light reflection over a broad spectrum by diversifying
the scattering routes from the nanotextured surface to the wide distributed
boundary micronanoscale grooves. This structure was achieved by hydrophobic
clustering and local aggregation of instantaneously melted Si nanocrystals
on a glass substrate under laser irradiation. This method can replace
the complicated conventional silicon processes, such as patterning
for selective Si formation, texturing for improved absorption, and
doping for modifying the electrical properties, because the proposed
method obviates the need for photolithography, chemical etching, vacuum
processes, and expensive wafers. Finally, black Si photosensor arrays
were successfully demonstrated by a low-cost solution process and
a laser growth sintering technique for microchannel fabrication. The
results show the great potential of the proposed fabrication method
for low-cost and sustainable production of highly sensitive optoelectronics
and as an alternative to conventional wafer-based photosensor manufacturing
techniques.