Self-assembly of artificial opals
has garnered significant interest
as a facile nanofabrication technique capable of producing highly
ordered structures for optical, electrochemical, biomolecular, and
thermal applications. In these applications, the optimum opal particle
diameter can vary by several orders of magnitude because the properties
of the resultant structures depend strongly on the feature size. However,
current opal fabrication techniques only produce high-quality structures
over a limited range of sphere sizes or require complex processes
and equipment. In this work, the rational and simple fabrication of
polycrystalline opals with diameters between 500 nm and 10 μm
was demonstrated using slope self-assembly of colloids suspended in
ethanol–water. The role of the various process parameters was
elucidated through a scaling-based model that accurately captures
the variations of opal substrate coverage for spheres of size 2 μm
or smaller. For spheres of 10 μm and larger, capillary forces
were shown to play a key role in the process dynamics. Based on these
insights, millimeter-scale monolayered opals were successfully fabricated,
while centimeter-scale opals were possible with sparse sphere stacking
or small uncovered areas. These insights provide a guide for the simple
and fast fabrication of opals that can be used as optical coatings,
templates for high power density electrodes, molecule templates, and
high-performance thermo-fluidic devices.