Ultrathin
polymer films (thinner than ∼100 nm) undergo spontaneous
rupture on a non-wetting surface with the appearance of random holes
due to interfacial van der Waal’s interaction or disjoining
pressure. These holes grow in size and coalesce into threadlike morphology,
which subsequently disintegrate in an isotropic array of nearly equal-sized
droplets, the size (d
D) and periodicity
(λD) of which scales with the initial film thickness
(h
F). We show that both λD and d
D of the dewetted droplets can
be modulated by adding trace amounts of nanoparticles (NPs) in the
films. While addition of higher proportion of NPs is known to stabilize
the films against dewetting, the presence of a lower amount of NPs
leads to non-monotonic variation of λD and d
D with h
F, with
the possible creation of miniaturized dewetted features under certain
conditions. We also show that λD and d
D of the dewetted films depend on whether dewetting is
engendered by thermal annealing of the film beyond the glass transition
temperature of the constituent polymer (T
G) or by exposing the film to solvent vapor (SV). Our findings reveal
that both λD and d
D are
much larger when the film (both with and without particles) is dewetted
in the SV atmosphere, arguably due to penetration of the solvent into
the film matrix, resulting in an increase in the effective thickness
of the film during dewetting. We show that in SV-mediated dewetting,
the much faster dynamics is attributed to solvent penetration through
the film and its wetting the substrate, rather than a drastic drop
in viscosity. We also observe that SV exposure not only leads to much
faster dewetting dynamics, but it also successfully engenders dewetting
in films with higher h
F, which remain
stable when annealed thermally.