Megalibraries are centimeter-scale chips containing millions
of
materials synthesized in parallel using scanning probe lithography.
As such, they stand to accelerate how materials are discovered for
applications spanning catalysis, optics, and more. However, a long-standing
challenge is the availability of substrates compatible with megalibrary
synthesis, which limits the structural and functional design space
that can be explored. To address this challenge, thermally removable
polystyrene films were developed as universal substrate coatings that
decouple lithography-enabled nanoparticle synthesis from the underlying
substrate chemistry, thus providing consistent lithography parameters
on diverse substrates. Multi-spray inking of the scanning probe arrays
with polymer solutions containing metal salts allows patterning of
>56 million nanoreactors designed to vary in composition and size.
These are subsequently converted to inorganic nanoparticles via reductive
thermal annealing, which also removes the polystyrene to deposit the
megalibrary. Megalibraries with mono-, bi-, and trimetallic materials
were synthesized, and nanoparticle size was controlled between 5 and
35 nm by modulating the lithography speed. Importantly, the polystyrene
coating can be used on conventional substrates like Si/SiOx, as well as substrates typically more difficult to pattern on, such
as glassy carbon, diamond, TiO2, BN, W, or SiC. Finally,
high-throughput materials discovery is performed in the context of
photocatalytic degradation of organic pollutants using Au–Pd–Cu
nanoparticle megalibraries on TiO2 substrates with 2,250,000
unique composition/size combinations. The megalibrary was screened
within 1 h by developing fluorescent thin-film coatings on top of
the megalibrary as proxies for catalytic turnover, revealing Au0.53Pd0.38Cu0.09-TiO2 as the
most active photocatalyst composition.