Formation
of inhomogeneous (in the form of a “coffee ring”)
or homogeneous deposits accompanies the drying of a particle-laden
drop. Invariably, this deposition occurs in a two-dimensional (2D)
space (x, y plane) (and might have
a finite thickness in z), where the evaporating drop
is positioned. Here, we show an interesting extension of this problem:
we demonstrate the occurrence of evaporation-mediated particle deposits
that span three dimensions (x, y, and z). The extent of the span in this 3rd dimension
(z) is comparable to the span in x and y and hence is much larger than the finite
thickness (in z) of the 2D deposits. Particle-laden
drops are introduced in an uncured and heavier (than the drop) polydimethysiloxane
(PDMS) film, enabling the drop to come to the uncured PDMS surface
and breach it and get partly exposed to the surrounding air enforcing
the onset of evaporation. The subsequent curing of the drop-laden
PDMS film ensures that the drop is occupying a three-dimensional (3D)
cavity; as a consequence, the evaporation-driven flow field, depending
on the particle sizes, leads to a deposition pattern that spans three
dimensions. We consider particles of three different sizes: coffee
particles (20–50 μm), silver nanoparticles (∼20
nm), and carbon nanotubes (CNTs) (1–2 μm). The coffee
particles form a ring-like deposit in the x, y plane, while the much smaller silver nanoparticles (NPs)
and CNTs form a 3D deposit that spans in x, y, and z directions. We anticipate that
the present finding of the evaporation-triggered three-dimensional
(3D) particle deposits will enable unprecedented self-assembly-driven
fabrication of various materials, structures, and functional devices
as well as patterning and coating in 3D spaces.