Rubbing a dry powder of particles in one direction between two rubbery substrates is found to be a quick and highly reproducible, yet inexpensive fabrication technique for assembling particle monolayers with perfect spatial registry on flat or curved surfaces. The optimum rubbing conditions - pressure and speed - for a single-crystal monolayer are shown to depend on particle size. Potential applications are in biosensors, photovoltaics, and light manipulators.

Highly stretchable conductive composite lines with an ordered zigzag structure are prepared. The high stretchability arises from the interpenetrating network between the polymer gel and Ag nanoparticles, as well as the ordered zigzag morphology. Double transfer of the structures in a perpendicular configuration allows for the fabrication of 2D stretchable electrodes.

Structural colors originate from purely physical structures. Scientists have been inspired to mimic the structures found in nature, the realization of these structures still presents a great challenge. We have recently introduced unidirectional rubbing of a dry particle powder on a rubbery surface as a quick, highly reproducible means to fabricate a single crystal monolayer assembly of particles over an unlimited area. This study extends the particle-rubbing process to a novel fine-art painting, structural color painting (SCP). SCP is based on structural coloring with varying iridescence according to the crystal orientation, as controlled by the rubbing direction. This painting technique can be applied on curved surfaces, which enriches the objects to be painted and helps the painter mimic the structures found in nature. It also allows for quick fabrication of complicated particle-assembly patterns, which enables replication of paintings.

This work introduces a robust means for excellent position registry of microparticles via a forced assembly technique on flexible or stretchable substrates. It is based on the dry powder rubbing process which allows assembly of a microparticle monolayer in a short time without requiring any solvent or thermal treatment. Elastic physical templates are used as substrates for the forced assembly in this study. Since the elastic templates can reduce the stress accumulation between the closely packed particles, they can minimize the defect formation in the particle assembly in large areas. The method can be used with powders comprising irregularly shaped particles with a relatively large size distribution that cannot be periodically ordered by conventional self-assembly. Furthermore, a non-closely packed particle array can be fabricated readily in large area, which is highly desirable for practical uses of the particle monolayers. The particle monolayers formed on the elastomer templates can be transferred to surfaces coated with thermoplastic block copolymers. Once transferred, the particle monolayers are flexible and stretchable over their entire surface. This work uses the particle monolayers on a large-area flexible substrate as photomasks to produce various photoresist patterns.

Well-defined ordered arrays of plasmonic nanostructures were fabricated on stretchable substrates and tunable plasmon-coupling-based sensing properties were comprehensively demonstrated upon extension and contraction. Regular nanoprism patterns consisting of Ag, Au and Ag/Au bilayers were constructed on the stretchable polydimethylsiloxane substrate. The nanoprisms had the same orientation over the entire substrate (3 × 3 cm) via metal deposition on a single-crystal microparticle monolayer assembly. The plasmonic sensor based on the Ag/Au bilayer showed a 6-fold enhanced surface enhanced Raman scattering signal under 20% uniaxial extension, whereas a 3-fold increase was observed upon 6% contraction, compared with the Au nanoprism arrays. The sensory behaviors were corroborated by finite-difference time-domain simulation, demonstrating the tunable electromagnetic field enhancement effect via the localized surface plasmon resonance coupling. The advanced flexible plasmonic-coupling-based devices with tunable and quantifiable performance herein suggested are expected to unlock promising potential in practical bio-sensing, biotechnological applications and optical devices.