A novel microfluidic molding process was used to form microscale features of gold nanoparticles on polyimide, glass, and silicon substrates. This technique uses permeation pumping to pattern and concentrate a nanoparticle ink inside microfluidic channels created in a porous polymer template in contact with a substrate. The nanoparticle ink is self-concentrated in the microchannels, resulting in dense, close-packed nanoparticle features. The method allows for better control over the structure of printed features at a resolution that is comparable to inkjet printing, and is purely additive with no residual layers or etching required. The process uses low temperatures and pressures and takes place in an ambient environment. After patterning, the gold nanoparticles were sintered into continuous and conductive gold traces.

Soft lithography methods are emerging as useful tools for high-resolution, three-dimensional patterning of polymers and nanoparticles. However, the low Young's modulus of the standard template material, poly(dimethylsiloxane) (PDMS), limits attainable resolution, fidelity, and alignment capability. While much research has been performed to find other more rigid polymer template materials, the high solvent and vapor permeability that is characteristic of PDMS is often sacrificed, preventing their use in those processes reliant on this property. In this work, a highly rigid, chemically robust, optically transparent and vapor-permeable poly(4-methyl-2-pentyne) template is developed. The combination of high rigidity and high vapor permeability enables high resolution patterning with simplified ink handling. This material was nanopatterned to create a template for patterning polymers and nanoparticles, achieving a resolution of better than 350 nm.

Nanoparticles and polymers have great potential for lowering cost and increasing functionality of printed sensors and electronics. However, creation of practical devices requires that many of these materials be patterned on a single substrate, and many current patterning processes can only handle a single material at a time, necessitating alignment of serial processing steps. Higher throughput and lower cost can be achieved by patterning multiple materials simultaneously. To this end, the microfluidic molding process is adapted to pattern various nanoparticle and polymer inks simultaneously, in a completely additive manner, with three-dimensional control and high relative positional accuracy between the different materials. A differential template distortion observed in channels containing different inks is analyzed and found to result from pressure force in the template due to flow of a highly viscous and highly concentrated ink in small channels. The resulting optimization between patterning speed and dimensional fidelity is discussed.

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The thermal flash method was developed to characterize the thermal diffusivity of micro/nanofibers without concern for thermal contact resistance, which is commonly a barrier to accurate thermal measurement of these materials. Within a scanning electron microscope, a micromanipulator supplies instantaneous heating to the micro/nanofiber, and the resulting transient thermal response is detected at a microfabricated silicon sensor. These data are used to determine thermal diffusivity. Glass fibers of diameter 15 microm had a measured diffusivity of 1.21x10(-7) m(2)/s; polyimide fibers of diameters 570 and 271 nm exhibited diffusivities of 5.97x10(-8) and 6.28x10(-8) m(2)/s, respectively, which compare favorably with bulk values.

High-resolution patterning of nanostructured materials into open templates is limited by the processes of creation and removal of the necessary template. In this work, a process for forming a micropatterned template from cellulose acetate polymer in situ on the substrate is demonstrated. Nanoparticles are patterned by evaporative self-assembly, and the template is removed by mechanical means. The process is demonstrated by patterning zinc oxide nanoparticles on silicon and cyclic olefin copolymer substrates and by creating a highly sensitive ultraviolet light detector.

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Noncontact thermal measurement techniques offer rapid thermal characterization without modification or destruction of the sample being studied. A simple and versatile method has been developed, termed the "numerical mirage method," that utilizes the transient photothermal deflection of a laser beam traversing a modulated temperature gradient. This method expands the range and simplifies the experimental procedure of traditional mirage methods. A numerical solver is used to create accurate deflection profile models and a linear curve fitting routine is developed, from which the thermal diffusivity of a material may be determined. This method allows for rapid modification of sample and heating configurations. Verification of the method is performed on bismuth and fused quartz reference samples, and good agreement with literature is obtained.