We present reflective plasmonic colors based on the concept of localized surface plasmon resonances (LSPR) for plastic consumer products. In particular, we bridge the widely existing technological gap between clean-room fabricated plasmonic metasurfaces and the practical call for large-area structurally colored plastic surfaces robust to daily life handling. We utilize the hybridization between LSPR modes in aluminum nanodisks and nanoholes to design and fabricate bright angle-insensitive colors that may be tuned across the entire visible spectrum.
Plasmonic metasurface coloration has attracted considerable attention in recent years due to its industrial potential. So far, demonstrations have been limited to small patterned areas fabricated using expensive techniques with limited scalability. This study elevates the technology beyond the common size and volume limitations of nanofabrication and demonstrates aluminum‐coated polymer‐based colored metasurfaces of square‐centimeter size by embossing, injection molding, roll‐to‐roll printing, and film insert molding. Different techniques are compared and the requirements and bottlenecks in terms of master fabrication, replication, metallization, and protection coating for large‐scale production of sub‐wavelength metasurfaces are discussed. Most notably, it is demonstrated that plasmonic metasurface colors are compatible with film insert molding. The results indicate a promising future for plasmonic colors as a viable alternative for decorating mass‐produced polymer parts.
Although metals are commonly shiny and highly reflective, we here show that thin metal films appear black when deposited on a dielectric with antireflective moth-eye nanostructures. The nanostructures were tapered and close-packed, with heights in the range 300-600 nm, and a lateral, spatial frequency in the range 5–7 μm−1. A reflectance in the visible spectrum as low as 6%, and an absorbance of 90% was observed for an Al film of 100 nm thickness. Corresponding experiments on a planar film yielded 80% reflectance and 20% absorbance. The observed absorbance enhancement is attributed to a gradient effect causing the metal film to be antireflective, analogous to the mechanism in dielectrics and semiconductors. We find that the investigated nanostructures have too large spatial frequency to facilitate efficient coupling to the otherwise non-radiating surface plasmons. Applications for decoration and displays are discussed.
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