Self-assembly of highly ordered micro- and nanoparticle deposits

The evaporation of particle-laden sessile droplets is associated with capillary-driven outward flow and leaves nonuniform coffee-ring-like particle patterns due to far-from-equilibrium effects. Traditionally, the surface energies of the drop and solid phases are tuned, or external forces are applied to suppress the coffee-ring; however, achieving a uniform and repeatable particle deposition is extremely challenging. Here, we report a simple, scalable, and noninvasive technique that yields uniform and exceptionally ordered particle deposits on a microscale surface area by placing the droplet on a near neutral-wet shadow mold attached to a hydrophilic substrate. The simplicity of the method, no external forces, and no tuning materials’ physiochemical properties make the present generic approach an excellent candidate for a wide range of sensitive applications. We demonstrate the utility of this method for fabricating ordered mono- and multilayer patternable coatings, producing nanofilters with controlled pore size, and creating reproducible functionalized nanosensors.