Rapid prototyping of patterned functional nanostructures

Living systems exhibit form and function on multiple length scales, and the prospect of imparting life-like qualities to man-made materials has inspired many recent efforts to devise hierarchical materials assembly strategies. For example, Yang et al. grew surfactant-templated mesoporous silica on hydrophobic patterns prepared by micro-contact printing {micro}CP{sup 3}. Trau et al. formed oriented mesoporous silica patterns, using a micro-molding in capillaries MIMIC technique, and Yang et al. combined MIMIC, polystyrene sphere templating, and surfactant-templating to create oxides with three levels of structural order. Overall, great progress has been made to date in controlling structure on scales ranging from several nanometers to several micrometers. However, materials prepared have been limited to oxides with no specific functionality, whereas for many of the envisioned applications of hierarchical materials in micro-systems, sensors, waveguides, photonics, and electronics, it is necessary to define both form and function on several length scales. In addition, the patterning strategies employed thus far require hours or even days for completion. Such slow processes are inherently difficult to implement in commercial environments. The authors have combined evaporation-induced (silica/surfactant) self-assembly EISA with rapid prototyping techniques like pen lithography, ink-jet printing, and dip-coating on micro-contact printed substrates to form hierarchically organized structures in seconds. In addition, by co-condensation of tetrafunctional silanes (Si(OR){sub 4}) with tri-functional organosilanes ((RO){sub 3}SiR{prime}){sup 12--14} or by inclusion of organic additives, the authors have selectively derivatized the silica framework with functional R{prime} ligands or molecules. The resulting materials exhibit form and function on multiple length scales: on the molecular scale, functional organic moieties are positioned on pore surfaces, on the mesoscale, monosized pores are organized into 1-, 2-, or 3-dimensional networks, providing size-selective accessibility from the gas or liquid phase, and on the macroscale, 2-dimensional arrays and fluidic or photonic systems may be defined