Nanomanufacturing

With the evolution of micro/nanotechnology, anodic aluminum oxide (AAO) has received attention for sensor applications due to its regular and high-aspect-ratio nanopore structure with an excellent sensing performance, especially for electrical and optical sensors. Here, we propose the application of these capacitance and porous properties in a facile nanoporous AAO liquid sensor and study an efficient and economical method for preparing AAO substrates for liquid-phase substance sensing. By applying hybrid pulse anodization (HPA), a growth rate of approximately 5.9 μm/h was achieved in AAO fabrication. Compared to traditional low-temperature (0–10 °C) and two-step anodization with a growth rate of 1–3 μm/h, this process is significantly improved. The effect of pore widening on the performance of electrical sensors is also investigated and discussed. After pore widening, the capacitance values of AAO for air as a reference and various liquids, namely deionized water, alcohol, and acetone, are measured as 3.8 nF, 295.3 nF, 243.5 nF, and 210.1 nF, respectively. These results align with the trend in the dielectric constants and demonstrate the ability to clearly distinguish between different substances. The mechanism of AAO capacitive liquid-phase sensors can mainly be explained from two perspectives. First, since an AAO capacitive sensor is a parallel capacitor structure, the dielectric constant of the substance directly influences the capacitance value. In addition, pore widening increases the proportion of liquid filling the structure, enabling the sensor to clearly differentiate between substances. The other is the affinity between the substance and the AAO sensor, which can be determined using a contact angle test. The contact angles are measured as values of 93.2° and 67.7° before and after pore widening, respectively. The better the substance can fully fill the pores, the higher the capacitance value it yields. Full article

Silver nanowires (AgNWs) have garnered significant attention in nanotechnology due to their unique mechanical and electrical properties and versatile applications. This review explores the synthesis of AgNWs, with a specific focus on the utilization of millifluidic flow reactors (MFRs) as a promising platform for controlled and efficient production. It begins by elucidating the exceptional characteristics and relevance of AgNWs in various technological domains and then delves into the principles and advantages of MFRs by showcasing their pivotal role in enhancing the precision and scalability of nanowire synthesis. Within this review, an overview of the diverse synthetic methods employed for AgNW production using MFRs is provided. Special attention is given to the intricate parameters and factors influencing synthesis and how MFRs offer superior control over these critical variables. Recent advances in this field are highlighted, revealing innovative strategies and promising developments that have emerged. As with any burgeoning field, challenges are expected, so future directions are explored, offering insights into the current limitations and opportunities for further exploration. In conclusion, this review consolidates the state-of-the-art knowledge in AgNW synthesis and emphasizes the critical role of MFRs in shaping the future of nanomaterial production and nanomanufacturing. Full article

Cerium oxide nanoparticles (CeO₂ NPs) have gained significant attention in various fields, including biomedicine, semiconductors, cosmetics, and fuel cells, due to their unique physico-chemical properties. Notably, green-synthesized CeO₂ NPs have demonstrated enhanced potential as drug carriers, particularly in biomedical applications such as anti-inflammatory, anticancer, antimicrobial, and anti-oxidant therapies. This study aimed to investigate the anticancer effects of cerium oxide nanoparticles synthesized using turmeric rhizomes on human lung cancer cells. The cytotoxicity and proliferation inhibition of these nanoparticles were assessed using MTT and Live/Dead assays, revealing a dose-dependent reduction in cell viability. Additionally, reactive oxygen species (ROS) generation was quantified through ROS assays, confirming oxidative stress induction as a key mechanism of cytotoxicity. Cell proliferation analysis further demonstrated that increasing concentrations of CeO₂ NPs significantly reduced the multiplication of healthy lung cancer cells. These findings highlight the potential of turmeric-derived CeO₂ NPs as a promising therapeutic agent for lung cancer treatment, warranting further exploration of their mechanism of action and in vivo efficacy. Full article

This study addresses the challenges of efficient, large-scale production of flexible transparent conducting electrodes (TCEs). We fabricate TCEs on polyethylene terephthalate (PET) substrates using a high-speed roll-to-roll (R2R) compatible method that combines gravure printing and photonic curing. The hybrid TCEs consist of Ag metal bus lines (Ag MBLs) coated with silver nanowires (AgNWs) and indium zinc oxide (IZO) layers. All materials are solutions deposited at speeds exceeding 10 m/min using gravure printing. We conduct a systematic study to optimize coating parameters and tune solvent composition to achieve a uniform AgNW network. The entire stack undergoes photonic curing, a low-energy annealing method that can be completed at high speeds and will not damage the plastic substrates. The resulting hybrid TCEs exhibit a transmittance of 92% averaged from 400 nm to 1100 nm and a sheet resistance of 11 Ω/sq. Mechanical durability is tested by bending the hybrid TCEs to a strain of 1% for 2000 cycles. The results show a minimal increase (<5%) in resistance. The high-throughput potential is established by showing that each hybrid TCE fabrication step can be completed at 30 m/min. We further fabricate methylammonium lead iodide solar cells to demonstrate the practical use of these TCEs, achieving an average power conversion efficiency (PCE) of 13%. The high-performance hybrid TCEs produced using R2R-compatible processes show potential as a viable choice for replacing vacuum-deposited indium tin oxide films on PET. Full article

A simple method is developed to produce free-standing films of polypyrrole (PPy) in one step. It consists of the interfacial polymerization (without surfactants) of pyrrole (dissolved in chloroform) with an oxidant (ammonium persulfate, dissolved in water). It is observed that the area of the formed film only depends on the size of the interface, achieving the manufacture of PPy films of up to 300 cm², with a thickness of 200 microns. Transmission electron microscopy (TEM) images show the presence of superimposed nanoplatelets of ca. 100 nm main axis. These nanoparticles seem to aggregate in two dimensions to form the free-standing film. Scanning electron microscopy (SEM) shows a compact surface with nanowires decorating the surface. PPy films show an electrical conductivity of 63 (±3) S cm⁻¹. PPy conductive films are then applied in the construction of an antenna that shows a response in two bands: at 1.52 GHz (−13.85 dB) and at 3.50 GHz (−33.55 dB). The values are comparable to those of other antennas built with different PPy films. The simple synthesis of large-area PPy films in a single step would allow the fabrication of large quantities of electronic elements (e.g., sensors) with uniform properties in a short time. Full article

A national energy crisis has emerged in South Africa due to the country’s increasing energy needs in recent years. The reliance on fossil fuels, especially oil and gas, is unsustainable due to scarcity, emissions, and environmental repercussions. Researchers from all over the world have recently concentrated their efforts on finding carbon-free, renewable, and alternative energy sources and have investigated microbiology and biotechnology as a potential remedy. The usage of microbial electrolytic cells (MECs) and microbial fuel cells (MFCs) is one method for resolving the problem. These technologies are evolving as viable options for hydrogen and bioenergy production. The renewable energy technologies initiative in South Africa, which is regarded as a model for other African countries, has developed in the allocation of over 6000 MW of generation capacity to bidders across several technologies, primarily wind and solar. With a total investment value of R33.7 billion, the Eastern Cape’s renewable energy initiatives have created 18,132 jobs, with the province awarded 16 wind farms and one solar energy farm. Utilizing wastewater as a source of energy in MFCs has been recommended as most treatments, such as activated sludge processes and trickling filter plants, require roughly 1322 kWh per million gallons, whereas MFCs only require a small amount of external power to operate. The cost of wastewater treatment using MFCs for an influent flow of 318 m³ h⁻¹ has been estimated to be only 9% (USD 6.4 million) of the total cost of treatment by a conventional wastewater treatment plant (USD 68.2 million). Currently, approximately 500 billion cubic meters of hydrogen (H₂) are generated worldwide each year, exhibiting a growth rate of 10%. This production primarily comes from natural gas (40%), heavy oils and naphtha (30%), coal (18%), electrolysis (4%), and biomass (1%). The hydrogen produced is utilized in the manufacturing of ammonia (49%), the refining of petroleum (37%), the production of methanol (8%), and in a variety of smaller applications (6%). Considering South Africa’s energy issue, this review article examines the production of wastewater and its impacts on society as a critical issue in the global scenario and as a source of green energy. Full article

Effective high-aspect-ratio molds that minimize vacuum processes are becoming increasingly important for producing metalenses and other devices. To fabricate a high-aspect-ratio structure, a metal film must be used as a mask for dry etching, typically achieved via vacuum deposition. To avoid this vacuum process, we devised a method to develop an etching mask in the air using silver ink. The manufacturing method involved filling the mold with silver ink, baking it, removing silver from the convex parts of the mold with a polyethylene terephthalate film, and placing silver from the concave parts of the mold on top of the ultraviolet (UV)-cured resin using ultraviolet-nanoimprint lithography. The transferred pattern had silver on the convex parts, which was used as a mask for the oxygen dry etching of the UV-curable resin. Consequently, high-aspect-ratio resin shapes were obtained from three types of nano- and micromolds. Additionally, a high-aspect-ratio resin with silver was used as a replica mold to form a silver pattern. This process is effective and allows high-aspect-ratio patterns to be obtained from master molds. Full article

This research discusses the fabrication of a nickel matrix nanocomposite reinforced with in situ synthesized layered Ni₃Al intermetallics using mechanical alloying (MA) and spark plasma sintering (SPS). In contrast to ex situ methods that frequently produce weak interfaces, the in situ approach enhances bonding and mechanical performance by using layered Ni₃Al reinforcements with excellent deformation resistance and load-bearing potential. Twenty-hour milled Ni-Al powders were annealed at 700 °C and consolidated using SPS, achieving approximately 96% theoretical density. The nanocomposite showed exceptional mechanical properties, with a hardness of 350 ± 15 HV in contrast to 200 ± 5 HV for pure Ni, along with higher wear resistance and reduced wear track depth. These improvements resulted from microstructural refinement and the development of hard intermetallic phases. X-ray diffraction (XRD) and transmission electron microscopy (TEM) confirmed the formation of a homogeneous layered Ni₃Al structure inside the matrix, showing a crystallite size of around 40 nm post-milling. Layered reinforcements enhanced matrix–reinforcement interactions, thereby minimizing common challenges in traditional composites. This innovative production technique highlights the future potential of Ni₃Al-reinforced nanocomposites as high-performance materials for advanced engineering applications, combining outstanding mechanical and tribological properties with strong structural integrity. Full article

The pervasive use of screens, averaging nearly 7 h per day globally between mobile phones, computers, notebooks and TVs, has sparked a growing desire to minimize reflections from ambient lighting and enhance readability in harsh lighting conditions, without the need to increase screen brightness. This demand highlights a significant need for advanced anti-glare (AG) technologies, to increase comfort and eventually reduce energy consumption of the devices. Currently used production technologies are limited in their texture designs, which can lead to suboptimal performance of the anti-glare texture. To overcome this design limitation and improve the performance of the anti-glare feature, this work reports a new, cost-effective, high-volume production method that enables much needed design freedom over a large area. This is achieved by combining mastering via large-area Laser Beam Lithography (LBL) and replication by Nanoimprint Lithography (NIL) processes. The environmental impact of the production method, such as regards material consumption, are considered, and the full cycle from design to final imprint is discussed. Full article

Optical fiber sensors have emerged as a critical sensing technology across various fields due to their advantages, including high potential bandwidth, electrical isolation that is safe for utilization in electrically hazardous environments, high reliability, and ease of maintenance. However, conventional optical fiber sensors face limitations in achieving high sensitivity and precision. The integration of nanostructures with advanced coating technology is one of the critical solutions to enhancing sensor functionality. This review examined nanostructure coating techniques that are compatible with optical fiber sensors and evaluated etching techniques for the improvement of optical fiber sensing technology. Techniques such as vapor deposition, laser deposition, and sputtering to coat the nanostructure of novel materials on the optical fiber sensors are analyzed. The ability of optical fiber sensors to interact with the environment via etching techniques is highlighted by comparing the sensing parameters between etched and bare optical fibers. This comprehensive overview aims to provide a detailed understanding of nanostructure coating and etching for optical fiber sensing and offer insights into the current state and future prospects of optical fiber sensor technology for sensing performance advancement, emphasizing its potential in future sensing applications and research directions. Full article

Initial studies indicate that structured polymer surfaces can support the attachment and biofilm formation of bacteria and thereby provide enhanced positive effects of beneficial bacteria, for instance in biocontrol in aquacultures. In this study, we demonstrate a test platform to further explore the surface topography for bacterial attachment and biofilm growth. It is based on a cyclic olefin copolymer (COC) materials platform, and nanoimprint technology was used for the replication of microstructures. The use of nanoimprint technology ensures precise micropattern transfer, enabling easy prototyping. Further, the process parameters of the mold preparation and nanoimprinting are discussed, with the purpose of optimizing the polymer pattern profile. This study has the potential to identify promising surfaces for biofilm growth of beneficial bacteria. Full article

Electrochemically anodized TiO₂ nanotube arrays (NTAs) were used as a support material for the electrodeposition of zinc nanoparticles. The morphology, composition, and crystallinity of the materials were examined using scanning electron microscopy (SEM). Electrochemical impedance spectroscopy (EIS) was performed to evaluate the electrochemical properties of TiO₂ NTAs. Annealing post-anodization was shown to be effective in lowering the impedance of the TiO₂ NTAs (measured at 1 kHz frequency). Zinc nanohexagons (NHexs) with a mean diameter of ~300 nm and thickness of 10–20 nm were decorated on the surface of TiO₂ NTAs (with a pore diameter of ~80 nm and tube length of ~5 µm) via an electrodeposition process using a zinc-containing deep eutectic solvent. EIS and CV tests were performed to evaluate the functionality of zinc-decorated TiO₂ NTAs (Zn/TiO₂ NTAs) for glucose oxidation applications. The Zn/TiO₂ NTA electrocatalysts obtained at 40 °C demonstrated enhanced glucose sensitivity (160.8 μA mM⁻¹ cm⁻² and 4.38 μA mM⁻¹ cm⁻²) over zinc-based electrocatalysts reported previously. The Zn/TiO₂ NTA electrocatalysts developed in this work could be considered as a promising biocompatible electrocatalyst material for in vivo glucose oxidation applications. Full article

The demands for high resolution fabrication processes are ever-increasing, with new and optimized methodologies being highly relevant across several scientific fields. We systematically investigated thermal scanning probe lithography process and detailed how tuning temperature and probe contact time on the sample can optimize patterning and achieve 10 nm resolution. Additionally, we propose a novel fabrication methodology that integrates thermal scanning probe lithography and bilayer liftoff, achieving sub-20 nm resolution of the final metallized structures. Each step of the process, from sample preparation to the final liftoff, is described in detail. We also present a quantitative analysis comparing the accuracy of the lithography process to that of the bilayer liftoff. Finally, we show the feasibility of using thermal scanning probe lithography for the fabrication of photonic devices by validating our work with promising dipole geometries for this field. Full article

Biosensors are a new type of sensor that utilize biologically sensitive materials and microbially active analytes to measure a variety of biological signals. The purpose of monitoring is achieved by combining these sensitive materials with analytes such as proteins, cells, viruses, and bacteria, inducing changes in their physical or chemical properties. The use of nanomaterials in fabricating surface acoustic wave (SAW) biosensors is particularly noteworthy for the label-free detection of organisms due to their compact size, portability, and high sensitivity. Recent advancements in the manufacturing techniques of SAW biosensors have significantly enhanced sensor performance and reliability. These techniques not only ensure precise control over sensor dimensions and material properties but also facilitate scalable and cost-effective production processes. As a result, SAW biosensors are poised to become powerful tools for various clinical and rapid detection applications. Full article

Active food packaging incorporated with natural plant extracts as food preservatives, which will totally replace chemical preservatives gradually, are of major interest. Sequentially to our and other scientists’ previous work, in this paper we present the results of a study on the development of a novel active food packaging film based on the incorporation of a natural-halloysite/carvacrol-extract nanohybrid with the commercially used low-density polyethylene. The corona-treatment procedure was employed to incorporate a natural preservative on to the optimum final film. Packaging films are formatted with and without incorporation of natural-halloysite/carvacrol-extract nanohybrid and are coated externally, directly or via corona-treatment, with carvacrol essential oil. Mechanical, physicochemical, and preservation tests indicated that the low-density polyethylene incorporated perfectly with a natural-halloysite/carvacrol-extract nanohybrid. The extra external coating of the film with pure carvacrol extract using the corona-treatment technique led to approximately 100% higher Young Modulus values, slightly decreased ultimate strength by 20%, and exhibited almost stable elongation at break properties. The water vapor and oxygen properties were increased by 45 and 43%, correspondingly, compared to those of pure low-density polyethylene film. Finally, the antioxidant activity of the corona-treated film increased by 28% compared to the untreated film coated with carvacrol because of the controlled release rate of the carvacrol. Full article

In this study, we investigate the potential of two-photon lithography (2PL) as a solution to the challenges encountered in conventional membrane fabrication techniques, aiming to fabricate tailor-made membranes with high-resolution submicron pore structures suitable for advanced applications. This approach led to the development of fabrication techniques and printed membranes that can be adapted to various lab-on-a-chip (LOC) devices. Membranes were fabricated with pore diameters as small as 0.57 µm and porosities of 4.5%, as well as with larger pores of approximately 3.73 µm in diameter and very high porosities that reached up to 60%. Direct 3D printing of membranes offers a pathway for fabricating structures tailored to specific applications in microfluidics, enabling more efficient separation processes at miniature scales. This research represents a significant step towards bridging the gap between membrane technology and microfluidics, promising enhanced capabilities for a wide array of applications in biotechnology, chemical analysis, and beyond. Full article

We have demonstrated a low-cost and simple method for the fabrication of large-area films using the electrodeposition technique. Fairly superior quality CuIn(Ga)Se₂ (CIGS) films were deposited by a one-step electrodeposition method using a salt bath followed by annealing in an argon atmosphere at 550 °C for 1 h. The X-ray analyses demonstrate that the films are crystalline in nature, having a chalcopyrite phase. However, the conversion efficiencies are found to be lower compared to other methods. Our results indicate that CIGS films can be produced effectively via a one-step electrodeposition method. The observed morphology can have a great impact on solar cell efficiency. With suitable modifications, this simple and cheaper manufacturing process will be the best alternative method to the vacuum deposition technique for the fabrication of reliable and flexible CIGS solar cells in the near future. Full article

LED devices are increasingly gaining importance in lithography approaches due to the fact that they can be used flexibly for mask-less patterning. In this study, we briefly report on developments in mask-free lithography approaches based on nano-LED devices and summarize our current achievements in the different building blocks needed for its application. Individually addressable nano-LED structures can form the basis for an unprecedented fast and flexible patterning, on demand, in photo-chemically sensitive films. We introduce a driving scheme for nano-LEDs in arrays serving for a singularly addressable approach. Furthermore, we discuss the challenges facing nano-LED fabrication and possibilities to improve their performance. Additionally, we introduce LED structures based on a hybrid nanocrystal/nano-LED approach. Lastly, we provide an outlook how this approach could further develop for next generation lithography systems. This technique has a huge potential to revolutionize the field and to contribute significantly to energy and resources saving device nanomanufacturing. Full article

Organic solar cells (OSCs) are becoming increasingly popular in the scientific community because of their many desirable properties. These features include solution processability, low weight, low cost, and the ability to process on a wide scale using roll-to-roll technology. Enhancing the efficiency of photovoltaic systems, particularly high-performance OSCs, requires study into not only material design but also interface engineering. This study demonstrated that two different types of OSCs based on the PTB7-Th:IEICO-4F and PM6:Y6 active layers use a ZnO bilayer electron transport layer (ETL). The ZnO bilayer ETL comprises a ZnO nanoparticle (ZnO NP) and a ZnO layer created from a sol-gel. The effect of incorporating ZnO NPs into the electron transport layer (ETL) was studied; in particular, the effects on the electrical, optical, and morphological properties of the initial ZnO ETL were analyzed. The ability of ZnO films to carry charges is improved by the addition of ZnO nanoparticles (NPs), which increase their conductivity. The bilayer structure had better crystallinity and a smoother film surface than the single-layer sol-gel ZnO ETL. This led to a consistent and strong interfacial connection between the photoactive layer and the electron transport layer (ETL). Therefore, inverted organic solar cells (OSCs) with PTB7-Th:IEICO-4F and PM6:Y6 as photoactive layers exhibit improved power conversion efficiency and other photovoltaic properties when using the bilayer technique. Full article