High-resolution direct patterning of gold nanoparticles by the microfluidic molding process

A novel microfluidic molding process was used to form microscale features of gold nanoparticles on polyimide, glass, and silicon substrates. This technique uses permeation pumping to pattern and concentrate a nanoparticle ink inside microfluidic channels created in a porous polymer template in contact with a substrate. The nanoparticle ink is self-concentrated in the microchannels, resulting in dense, close-packed nanoparticle features. The method allows for better control over the structure of printed features at a resolution that is comparable to inkjet printing, and is purely additive with no residual layers or etching required. The process uses low temperatures and pressures and takes place in an ambient environment. After patterning, the gold nanoparticles were sintered into continuous and conductive gold traces.