Hierarchical Control of Polymer Composite Nano- and Micro-Structure with Lithography

We have developed a novel composite film fabrication process that utilizes the soft lithographic approach, Particle Replication in Nonwetting Templates (PRINT). This process was found to be a very viable approach to the fabrication of well-structured, multifunctional polymer composite thin films. Particle aggregation was completely eliminated as discretely molded particles with specific shape, size and composition were maintained in well-defined arrays determined by the silicon master template. Both all-organic and polymer-ceramic composites have been generated using this technique with particle inclusions ranging in size from 200 nm to 20 μm. The composition of the composite was well-controlled with both cross-linked and thermoplastic polymeric continuous phases, as well as particle compositions ranging from cross-linked polymeric resins to the inorganic oxide, barium titanate.