The extremely large optical extinction coefficient of gold nanorods (Au-NRs) enables their use in a diverse array of technologies, rnging from plasmonic imaging, therapeutics and sensors, to large area coatings, filters, and optical attenuators. Development of the latter technologies has been hindered by the lack of cost-effective, large volume production. This is due in part to the low reactant concentration required for symmetry breaking in conventional seed-mediated synthesis. Direct scale up of laboratory procedures has limited viability because of excessive solvent volume, exhaustive postsynthesis purification processes, and the generation of large amounts of waste (e.g., hexadecyltrimethylammonium bromide(CTAB)). Following recent insights into the growth mechanism of Au-NRs and the role of seed development, we modify the classic seed-mediated synthesis via temporal control of seed and reactant concentration to demonstrate production of Au-NRs at more than 100-times the conventional concentration, while maintaining independent control and narrow distribution of nanoparticle dimensions, aspect ratio, and volume. Thus, gram scale synthesis of Au-NRs with prescribed aspect ratio and volume is feasible in a 100 mL reactor with 1/100th of organic waste relative to conventional approaches. Such scale-up techniques are crucial to cost-effectively meet the increased demand for large quantities of Au-NRs in emerging applications.

The stability of polymer thin films is crucial to a broad range of technologies, including sensors, energy storage, filtration, and lithography. Recently, the demonstration of rapid deposition on solid substrates of ordered monolayers of polymer grafted nanoparticles (PGN) has increased potential for inks to additively manufacture such components. Herein, enhanced stability against dewetting of these self-assembled PGN films (gold nanoparticle functionalized with polystyrene (AuNP-PS)) is discussed in context to linear polystyrene (PS) analogues using high throughput surface gradients: surface energy (20−45 mN/m) and temperature (90−160 °C). PGNs exhibit a lower surface (γ p ) and interfacial (γ sp ) energy relative to linear polymers, which results in increased thermal and energetic stability by 10−25 °C and 5−15 mN/m, respectively. This enhanced wetting−dewetting transition is qualitatively consistent with the behavior of star macromolecules and depends on the architecture of the polymer canopy. Increased film stability through canopy architecture expands the manufacturability of thin film hybrids and refines postprocessing conditions to maximize local PGN order.

Solution-based printing of anisotropic nanostructures is foundational to many emerging technologies, such as energy storage devices, photonic elements, and sensors. Methods to rapidly (>mm/s) manufacture large area assemblies (≫cm2) with simultaneous control of thickness (<10 nm), nanoparticle spacing (<5 nm), surface roughness (<5 nm), and global and local orientational order are still lacking. Herein, we demonstrate such capability using flow-coating to fabricate robust, self-supporting mono- and bilayer films of polystyrene-grafted gold nanorods (PS-AuNRs) onto solid substrates. The relationship among solvent evaporation, deposition speed, substrate surface energy, concentration, and film thickness for solutions of such hairy hybrid nanoparticles spans the Landau–Levich and evaporative film formation regimes. In the Landau–Levich regime, solvent evaporation rapidly concentrates the PS-AuNRs, leading to the formation of thin films with distinct, randomized side-by-side domains. Alternatively, processing at slower velocities in the evaporative regime results in the global alignment of PS-AuNRs. Processing speed and substrate surface energy afford tuning of the film’s optical extinction of a given PS-AuNR via fine control of inter-rod distance and subsequent plasmonic coupling between neighboring nanorods. Because the concept of the polymer-grafted nanorod can be expanded to a variety of different polymer canopies, shapes, and core materials, the processing–structure relationships established in this work will have important implications on the future development of anisotropic nanostructure-based applications.