Nanomanufacturing

This research discusses the fabrication of a nickel matrix nanocomposite reinforced with in situ synthesized layered Ni₃Al intermetallics using mechanical alloying (MA) and spark plasma sintering (SPS). In contrast to ex situ methods that frequently produce weak interfaces, the in situ approach enhances bonding and mechanical performance by using layered Ni₃Al reinforcements with excellent deformation resistance and load-bearing potential. Twenty-hour milled Ni-Al powders were annealed at 700 °C and consolidated using SPS, achieving approximately 96% theoretical density. The nanocomposite showed exceptional mechanical properties, with a hardness of 350 ± 15 HV in contrast to 200 ± 5 HV for pure Ni, along with higher wear resistance and reduced wear track depth. These improvements resulted from microstructural refinement and the development of hard intermetallic phases. X-ray diffraction (XRD) and transmission electron microscopy (TEM) confirmed the formation of a homogeneous layered Ni₃Al structure inside the matrix, showing a crystallite size of around 40 nm post-milling. Layered reinforcements enhanced matrix–reinforcement interactions, thereby minimizing common challenges in traditional composites. This innovative production technique highlights the future potential of Ni₃Al-reinforced nanocomposites as high-performance materials for advanced engineering applications, combining outstanding mechanical and tribological properties with strong structural integrity. Full article

The pervasive use of screens, averaging nearly 7 h per day globally between mobile phones, computers, notebooks and TVs, has sparked a growing desire to minimize reflections from ambient lighting and enhance readability in harsh lighting conditions, without the need to increase screen brightness. This demand highlights a significant need for advanced anti-glare (AG) technologies, to increase comfort and eventually reduce energy consumption of the devices. Currently used production technologies are limited in their texture designs, which can lead to suboptimal performance of the anti-glare texture. To overcome this design limitation and improve the performance of the anti-glare feature, this work reports a new, cost-effective, high-volume production method that enables much needed design freedom over a large area. This is achieved by combining mastering via large-area Laser Beam Lithography (LBL) and replication by Nanoimprint Lithography (NIL) processes. The environmental impact of the production method, such as regards material consumption, are considered, and the full cycle from design to final imprint is discussed. Full article

Optical fiber sensors have emerged as a critical sensing technology across various fields due to their advantages, including high potential bandwidth, electrical isolation that is safe for utilization in electrically hazardous environments, high reliability, and ease of maintenance. However, conventional optical fiber sensors face limitations in achieving high sensitivity and precision. The integration of nanostructures with advanced coating technology is one of the critical solutions to enhancing sensor functionality. This review examined nanostructure coating techniques that are compatible with optical fiber sensors and evaluated etching techniques for the improvement of optical fiber sensing technology. Techniques such as vapor deposition, laser deposition, and sputtering to coat the nanostructure of novel materials on the optical fiber sensors are analyzed. The ability of optical fiber sensors to interact with the environment via etching techniques is highlighted by comparing the sensing parameters between etched and bare optical fibers. This comprehensive overview aims to provide a detailed understanding of nanostructure coating and etching for optical fiber sensing and offer insights into the current state and future prospects of optical fiber sensor technology for sensing performance advancement, emphasizing its potential in future sensing applications and research directions. Full article

Initial studies indicate that structured polymer surfaces can support the attachment and biofilm formation of bacteria and thereby provide enhanced positive effects of beneficial bacteria, for instance in biocontrol in aquacultures. In this study, we demonstrate a test platform to further explore the surface topography for bacterial attachment and biofilm growth. It is based on a cyclic olefin copolymer (COC) materials platform, and nanoimprint technology was used for the replication of microstructures. The use of nanoimprint technology ensures precise micropattern transfer, enabling easy prototyping. Further, the process parameters of the mold preparation and nanoimprinting are discussed, with the purpose of optimizing the polymer pattern profile. This study has the potential to identify promising surfaces for biofilm growth of beneficial bacteria. Full article

Electrochemically anodized TiO₂ nanotube arrays (NTAs) were used as a support material for the electrodeposition of zinc nanoparticles. The morphology, composition, and crystallinity of the materials were examined using scanning electron microscopy (SEM). Electrochemical impedance spectroscopy (EIS) was performed to evaluate the electrochemical properties of TiO₂ NTAs. Annealing post-anodization was shown to be effective in lowering the impedance of the TiO₂ NTAs (measured at 1 kHz frequency). Zinc nanohexagons (NHexs) with a mean diameter of ~300 nm and thickness of 10–20 nm were decorated on the surface of TiO₂ NTAs (with a pore diameter of ~80 nm and tube length of ~5 µm) via an electrodeposition process using a zinc-containing deep eutectic solvent. EIS and CV tests were performed to evaluate the functionality of zinc-decorated TiO₂ NTAs (Zn/TiO₂ NTAs) for glucose oxidation applications. The Zn/TiO₂ NTA electrocatalysts obtained at 40 °C demonstrated enhanced glucose sensitivity (160.8 μA mM⁻¹ cm⁻² and 4.38 μA mM⁻¹ cm⁻²) over zinc-based electrocatalysts reported previously. The Zn/TiO₂ NTA electrocatalysts developed in this work could be considered as a promising biocompatible electrocatalyst material for in vivo glucose oxidation applications. Full article

The demands for high resolution fabrication processes are ever-increasing, with new and optimized methodologies being highly relevant across several scientific fields. We systematically investigated thermal scanning probe lithography process and detailed how tuning temperature and probe contact time on the sample can optimize patterning and achieve 10 nm resolution. Additionally, we propose a novel fabrication methodology that integrates thermal scanning probe lithography and bilayer liftoff, achieving sub-20 nm resolution of the final metallized structures. Each step of the process, from sample preparation to the final liftoff, is described in detail. We also present a quantitative analysis comparing the accuracy of the lithography process to that of the bilayer liftoff. Finally, we show the feasibility of using thermal scanning probe lithography for the fabrication of photonic devices by validating our work with promising dipole geometries for this field. Full article

Biosensors are a new type of sensor that utilize biologically sensitive materials and microbially active analytes to measure a variety of biological signals. The purpose of monitoring is achieved by combining these sensitive materials with analytes such as proteins, cells, viruses, and bacteria, inducing changes in their physical or chemical properties. The use of nanomaterials in fabricating surface acoustic wave (SAW) biosensors is particularly noteworthy for the label-free detection of organisms due to their compact size, portability, and high sensitivity. Recent advancements in the manufacturing techniques of SAW biosensors have significantly enhanced sensor performance and reliability. These techniques not only ensure precise control over sensor dimensions and material properties but also facilitate scalable and cost-effective production processes. As a result, SAW biosensors are poised to become powerful tools for various clinical and rapid detection applications. Full article

Active food packaging incorporated with natural plant extracts as food preservatives, which will totally replace chemical preservatives gradually, are of major interest. Sequentially to our and other scientists’ previous work, in this paper we present the results of a study on the development of a novel active food packaging film based on the incorporation of a natural-halloysite/carvacrol-extract nanohybrid with the commercially used low-density polyethylene. The corona-treatment procedure was employed to incorporate a natural preservative on to the optimum final film. Packaging films are formatted with and without incorporation of natural-halloysite/carvacrol-extract nanohybrid and are coated externally, directly or via corona-treatment, with carvacrol essential oil. Mechanical, physicochemical, and preservation tests indicated that the low-density polyethylene incorporated perfectly with a natural-halloysite/carvacrol-extract nanohybrid. The extra external coating of the film with pure carvacrol extract using the corona-treatment technique led to approximately 100% higher Young Modulus values, slightly decreased ultimate strength by 20%, and exhibited almost stable elongation at break properties. The water vapor and oxygen properties were increased by 45 and 43%, correspondingly, compared to those of pure low-density polyethylene film. Finally, the antioxidant activity of the corona-treated film increased by 28% compared to the untreated film coated with carvacrol because of the controlled release rate of the carvacrol. Full article

In this study, we investigate the potential of two-photon lithography (2PL) as a solution to the challenges encountered in conventional membrane fabrication techniques, aiming to fabricate tailor-made membranes with high-resolution submicron pore structures suitable for advanced applications. This approach led to the development of fabrication techniques and printed membranes that can be adapted to various lab-on-a-chip (LOC) devices. Membranes were fabricated with pore diameters as small as 0.57 µm and porosities of 4.5%, as well as with larger pores of approximately 3.73 µm in diameter and very high porosities that reached up to 60%. Direct 3D printing of membranes offers a pathway for fabricating structures tailored to specific applications in microfluidics, enabling more efficient separation processes at miniature scales. This research represents a significant step towards bridging the gap between membrane technology and microfluidics, promising enhanced capabilities for a wide array of applications in biotechnology, chemical analysis, and beyond. Full article

We have demonstrated a low-cost and simple method for the fabrication of large-area films using the electrodeposition technique. Fairly superior quality CuIn(Ga)Se₂ (CIGS) films were deposited by a one-step electrodeposition method using a salt bath followed by annealing in an argon atmosphere at 550 °C for 1 h. The X-ray analyses demonstrate that the films are crystalline in nature, having a chalcopyrite phase. However, the conversion efficiencies are found to be lower compared to other methods. Our results indicate that CIGS films can be produced effectively via a one-step electrodeposition method. The observed morphology can have a great impact on solar cell efficiency. With suitable modifications, this simple and cheaper manufacturing process will be the best alternative method to the vacuum deposition technique for the fabrication of reliable and flexible CIGS solar cells in the near future. Full article

LED devices are increasingly gaining importance in lithography approaches due to the fact that they can be used flexibly for mask-less patterning. In this study, we briefly report on developments in mask-free lithography approaches based on nano-LED devices and summarize our current achievements in the different building blocks needed for its application. Individually addressable nano-LED structures can form the basis for an unprecedented fast and flexible patterning, on demand, in photo-chemically sensitive films. We introduce a driving scheme for nano-LEDs in arrays serving for a singularly addressable approach. Furthermore, we discuss the challenges facing nano-LED fabrication and possibilities to improve their performance. Additionally, we introduce LED structures based on a hybrid nanocrystal/nano-LED approach. Lastly, we provide an outlook how this approach could further develop for next generation lithography systems. This technique has a huge potential to revolutionize the field and to contribute significantly to energy and resources saving device nanomanufacturing. Full article

Organic solar cells (OSCs) are becoming increasingly popular in the scientific community because of their many desirable properties. These features include solution processability, low weight, low cost, and the ability to process on a wide scale using roll-to-roll technology. Enhancing the efficiency of photovoltaic systems, particularly high-performance OSCs, requires study into not only material design but also interface engineering. This study demonstrated that two different types of OSCs based on the PTB7-Th:IEICO-4F and PM6:Y6 active layers use a ZnO bilayer electron transport layer (ETL). The ZnO bilayer ETL comprises a ZnO nanoparticle (ZnO NP) and a ZnO layer created from a sol-gel. The effect of incorporating ZnO NPs into the electron transport layer (ETL) was studied; in particular, the effects on the electrical, optical, and morphological properties of the initial ZnO ETL were analyzed. The ability of ZnO films to carry charges is improved by the addition of ZnO nanoparticles (NPs), which increase their conductivity. The bilayer structure had better crystallinity and a smoother film surface than the single-layer sol-gel ZnO ETL. This led to a consistent and strong interfacial connection between the photoactive layer and the electron transport layer (ETL). Therefore, inverted organic solar cells (OSCs) with PTB7-Th:IEICO-4F and PM6:Y6 as photoactive layers exhibit improved power conversion efficiency and other photovoltaic properties when using the bilayer technique. Full article

In this work, three different coating techniques are compared and their applicability for ultraviolet nanoimprint lithography (UV-NIL) is investigated. As UV-NIL is considered a suitable volume manufacturing production solution for various emerging applications, it is mandatory to consider environmental aspects such as operational energy use and material consumption as well as waste management. In this paper, spin coating, spray coating, and inkjet coating are used to coat both a high refractive index resin (n = 1.9) and a filler-free resin (n = 1.5), respectively. Variable Angle Spectroscopy Ellipsometry (VASE) was used to analyze the influence of different process parameters on the resin thickness as well as to compare the refractive index achieved from each coating technology. Finally, the applicability of the different coating methods for UV-NIL was investigated by imprinting the resin layers with different test structures. For the final imprints, the resolution, the surface roughness, and the pattern fidelity over 25 imprints was assessed using AFM. Finally, a comparison of the resin consumption and the process time was performed for each coating method. Full article

Humidity nanosensors play a vital role in modern technology industries, including weather forecasts, industrial manufacturing, agriculture, food and chemistry storage. In recent years, research on humidity sensors has focused on different materials such as ceramics, polymers, carbon-based materials, semiconductors, MXenes or triboelectric nanogenerators, each with their own advantages and disadvantages. Among them, anodic aluminum oxide (AAO) is a well-known ceramic humidity sensor material with a long history of research and development. AAO humidity sensors offer advantages such as simple manufacturing processes, controllable nanostructures, high thermal stability and biocompatibility. However, traditional AAO fabrication still has disadvantages like high costs and longer process times. Hence, finding a low-cost and efficient method to fabricate AAO for controlling different nanostructures to meet the requirements is consistently a major research topic. From our previous studies, we have studied the relationship between the AAO capacitive humidity sensor and its nanostructures. In this paper, we explore the effect of an AAO nanoporous structure controlled by an anodization voltage of 20–40 V on the resistive-type humidity sensor performance instead of a capacitive one. We efficiently apply one-step hybrid pulse anodization at 25 °C to significantly reduce the processing time compared to the traditional two-step process under 0–10 °C. The AAO nanostructures and their impact on sensor measurements of humidity at 20–80 RH% will be discussed in detail. An electrical resistive sensing mechanism is established for further performance improvement by controlling anodization voltage. Full article

The paper presents the results of a study on the effectiveness of few-layer graphene synthesized under SHS conditions from lignin as a modifying additive in creating composite pyrotechnic complexes based on porous silicon and calcium perchlorate. It was found that the addition of few-layer graphene (20–30 wt. %) could significantly increase the probability of the ignition of pyrotechnic compositions by laser diode (infrared) radiation (wavelength of 976 nm and power of 15 MW/m²) compared to the initial pyrotechnic compositions. Using few-layer graphene also leads to a sharp increase in sensitivity to infrared laser radiation and the initiation of explosive transformations in retrofitted pyrotechnic compositions compared to the initial pyrotechnic compositions. Due to the high productivity and low cost of the technique for synthesizing few-layer graphene, the use of composite pyrotechnic compositions modified with few-layer graphene is profitable in the actual industry. A phenomenological model of the formation mechanism of 2D graphene structures under the conditions of the SHS process is proposed. Full article

In this study, we investigated the influence of γ-irradiation (0, 50, and 100 kGy) doses on the chemical and mechanical properties of biodegradable poly(hydroxybutyrate-valerate)/poly(caprolactone) (PHBV/PCL) polymer blends rich in low-molar-mass PCL, which were prepared using a co-rotating twin-screw extruder. In parallel, the density functional theory (DFT) and the time-dependent DFT (TD-DFT) methods were used together with a model containing four monomer units to provide an insight into the electronic structure, chemical bonds, and spectroscopic (such as Nuclear Magnetic Resonance (NMR) and Ultraviolet-visible (UV-vis)) properties of PHBV and PCL blend phases, which are critical for predicting and designing new materials with desired properties. We found that an increase in γ-irradiation doses caused splitting instead of crosslinks in the polymer chains, which led to evident deformation and an increase in tensile strength at break of 2.0 to 5.7 MPa for the PHBV/PCL blend. Further, this led to a decrease in crystallinity and proved the occurrence of a more favorable interaction between the blend phases. Full article

We present a theoretical approach for the in silico generation of new polymer structures for the systematic search for new materials with advanced properties. It is based on Bicerano’s Regression Model (RM), which uses the structure of the smallest repeating unit (SRU) for fast and adequate prediction of polymer properties. We have developed the programs (a) GenStruc, for generating the new polymer SRUs using the enumeration and Monte Carlo algorithms, and (b) PolyPred, for predicting properties for a given input polymer as well as for multiple structures stored in the database files. The structure database from the original Bicerano publication is used to create databases of backbones and pendant groups. A database of 5,142,153 unique SRUs is generated using the scaffold-based combinatorial method. We show that using only known backbones of the polymer SRU and varying the pendant groups can significantly improve the predicted extreme values of polymer properties. Analysis of the obtained results for the dielectric constant and refractive index shows that the values of the dielectric constant are higher for polyhydrazides than for polyhydroxylamines. The high value predicted for the refractive index of polythiophene and its derivatives is in agreement with the experimental data. Full article

In the manufacturing sector, transport phenomena near the stagnation region are frequent, particularly in the polymer and extrusion processes, which require continuous improvement to raise the process’s quality standards. The aim of this study is to explore the improvement of heat and mass transmission using unsteady magnetohydrodynamic (MHD) hybrid nanofluid (HNF) flow over a stretching/shrinking cylinder with variable viscosity and Stefan blowing. The governed equations of heat and mass transfer processes are converted into ordinary differential equations (ODEs) using the appropriate transformations, and the resulting equations are then solved using the MATLAB package bvp4c. With an upsurge in the volume fraction of nanoparticles, the skin friction increases, but the reverse trend is detected with negative values for the unsteadiness constraint. The use of 2D graphs to show how important parameters affect the velocity, temperature, and concentration is thoroughly discussed. There is a discussion of the quantitative findings from the wall shear factor and the heat and mass transfer rates calculated for the stretching/shrinking cases. Full article

Investigating the behavior of cardiomyocytes is an important part of drug development. We present a structure and a related nanoimprint-based fabrication method, where the cardiomyocytes form isolated fibers, which is beneficial for drug testing, more closely representing the structure of the cardiomyocytes in vivo. We found that channel structures with walls with a rough top surface stimulate cardiomyocytes to form such fibers, as desired. Nanoimprint lithography is used as a fast and cost-efficient method to fabricate our hierarchically structured cell growth substrates. Full article