Scientists at the California Institute of Technology have conducted experiments confirming which of three possible mechanisms is responsible for the spontaneous formation of three-dimensional (3-D) pillar arrays in nanofilms (polymer films that are billionths of a meter thick). These protrusions appear suddenly when the surface of a molten nanofilm is exposed to an extreme temperature gradient and self-organize into hexagonal, lamellar, square, or spiral patterns. This unconventional means of patterning films is being developed by Sandra Troian, professor of applied physics, aeronautics, and mechanical engineering at Caltech, who uses modulation of surface forces to shape and mold liquefiable nanofilms into 3-D forms. “My ultimate goal is to develop a suite of 3-D lithographic techniques based on remote, digital modulation of thermal, electrical, and magnetic surface forces,” Troian says. Confirmation of the correct mechanism has allowed her to deduce the maximum resolution or minimum feature size ultimately possible with these patterning techniques.
