Massively Scalable Self-Assembly of Nano and Microparticle Monolayers via Aerosol Assisted Deposition

An extremely rapid process for self-assembling well-ordered, nano, and
microparticle monolayers via a novel aerosolized method is presented. The
novel technique can reach monolayer self-assembly rates as high as 268 cm2
min−1 from a single aerosolizing source and methods to reach faster
monolayer self-assembly rates are outlined. A new physical mechanism
describing the self-assembly process is presented and new insights enabling
high-efficiency nanoparticle monolayer self-assembly are developed. In
addition, well-ordered monolayer arrays from particles of various sizes,
surface functionality, and materials are fabricated. This new technique enables
a 93× increase in monolayer self-assembly rates compared to the current
state of the art and has the potential to provide an extremely low-cost option
for submicron nanomanufacturing.