D. S. Deng

Structured spheres generated by an in-fibre fluid instability

From drug delivery to chemical and biological catalysis and cosmetics, the need for efficient fabrication pathways for particles over a wide range of sizes, from a variety of materials, and in many different structures has been well established. Here we harness the inherent scalability of fibre production and an in-fibre Plateau–Rayleigh capillary instability for the fabrication of uniformly sized, structured spherical particles spanning an exceptionally wide range of sizes: from 2 mm down to 20 nm. Thermal processing of a multimaterial fibre controllably induces the instability, resulting in a well-ordered, oriented emulsion in three dimensions. The fibre core and cladding correspond to the dispersed and continuous phases, respectively, and are both frozen in situ on cooling, after which the particles are released when needed. By arranging a variety of structures and materials in a macroscopic scaled-up model of the fibre, we produce composite, structured, spherical particles, such as core–shell particles, two-compartment ‘Janus’ particles, and multi-sectioned ‘beach ball’ particles. Moreover, producing fibres with a high density of cores allows for an unprecedented level of parallelization. In principle, 108 50-nm cores may be embedded in metres-long, 1-mm-diameter fibre, which can be induced to break up simultaneously throughout its length, into uniformly sized, structured spheres.

Processing and properties of centimeter-long, in-fiber, crystalline-selenium filaments

We report on the fabrication and characterization of globally ordered crystalline selenium filaments with diameters about 200 nm and aspect ratios upwards of 105. Amorphous Se filaments are fabricated by a recently developed approach in which a thin film evolves into an ordered array of filaments in fiber. Single-crystal and polycrystalline filaments are attained with a postdrawing annealing procedure. Arrays of two-cm-long crystalline nanowires, electrically contacted to external circuitry through the fiber end facets, exhibit a two-orders-of-magnitude change in conductivity between dark and illuminated states. These results hold promise for the fabrication of filament-detector arrays that may be integrated with large-area electronics.

In-Fiber Semiconductor Filament Arrays

We report a novel physical phenomenon in which a cylindrical shell undergoing a scaling process evolves into an ordered array of filaments upon reaching a characteristic thickness. We observe that the tendency to breakup is related to the material viscosity in a manner reminiscent of capillary instability. However, unlike the classical breakup of a fluid cylinder into droplets, the structural evolution in our system occurs exclusively in the cross sectional plane while uniformity is maintained in the axial direction. We propose a fluid front instability mechanism to account for the observed phenomena. The fleeting evolution of fluid breakup from a thin film to a filament array is captured in the frozen state by a thermal drawing process which results in extended lengths of solid sub-100 nm filaments encapsulated within a polymer fiber. Hundreds of glassy semiconductor filament arrays are precisely oriented within a polymer fiber matrix making electrical connections trivial. This approach offers unique opportunities for fabrication of nanometer scale devices of unprecedented lengths allowing simplified access and connectivity.

Thermal drawing of high-density macroscopic arrays of well-ordered sub-5-nm-diameter nanowires.

We investigate the lower limit of nanowire diameters stably produced by the process of thermal fiber drawing and fiber tapering. A centimeter-scale macroscopic cylindrical preform containing the nanowire material in the core encased in a polymer scaffold cladding is thermally drawn in the viscous state to a fiber. By cascading several iterations of the process, continuous reduction of the diameter of an amorphous semiconducting chalcogenide glass is demonstrated. Starting from a 10-mm-diameter rod we thermally draw hundreds of meters of continuous sub-5-nm-diameter nanowires. Using this approach, we produce macroscopic lengths of high-density, well-ordered, globally oriented nanowire arrays.

Observation of the Plateau-Rayleigh capillary instability in multi-material optical fibers

We report the observation of the Plateau-Rayleigh capillary instability during the tapering of a multi-material optical fiber. The fiber core is a glass, and the cladding is an amorphous polymer. The instability is manifested in the breakup of the core into a periodic string of size-tunable micro-scale droplets embedded along the fiber axis. The particle diameters may be tuned in the 1–20 μm range through control of the tapering speed and temperature. Extending this approach to the fabrication of polymer and glass nanoparticles appears feasible.

Exploration of in-fiber nanostructures from capillary instability

A new class of multi-material fiber that incorporates micrometer-thickness concentric-cylindrical sheets of glass into polymer matrix has emerged. The ultimate lower limit of feature size and recent observation of interesting instability phenomenon in fiber system motivate us to examine fluid instabilities during the complicated thermal drawing fabrication processing. In this paper, from the perspective of a single instability mechanism, classical Plateau-Rayleigh instabilities in the form of radial fluctuation, we explore the stability of various microstructures (such as shells and filaments) in our composite fibers. The attained uniform structures are consistent with theoretical analysis. Furthermore, a viscous materials map is established from calculations and agrees well with various identified materials. These results not only shed insights into other forms of fluid instabilities, but also provide guidance to achieve more diverse nanostructures (such as filaments, wires, and particles) in the microstructured fibers.

Linear stability analysis of capillary instabilities for concentric cylindrical shells

Center for Materials Science and Engineering at MIT (National Science Foundation (U.S.) (MRSEC program award DMR-0819762) )

In-fiber fabrication of size-controllable structured particles

We present an approach for fabricating single-material and multi-material structured spherical particles in the size range 1 millimeter to 50 nanometers that makes use of the Plateau-Rayleigh capillary instability in a multi-material fiber.