Pattern transfer nanomanufacturing using magnetic recording for programmed nanoparticle assembly

We report a novel nanomanufacturing technique that incorporates patterned arrays built entirely from Fe₃O₄ nanoparticles into a flexible and transparent polymer film. First, the nanoparticles are patterned using the enormous magnetic field gradients at the surface of commercial disk drive media, and then the resulting architecture is transferred to the surface of a polymer film by spin-coating and peeling. Since the particles are immobilized by the field gradients during the spin-coating process, the patterned array is preserved after peeling. To demonstrate the potential of this technology, we fabricate a 5 mm diameter all-nanoparticle diffraction grating capable of producing a white-light optical spectrum. We also demonstrate several extensions to this technology, where, by adding an external magnetic field during assembly, we create both periodic variations in topography, as well as a nanocomposite with two vertically and horizontally separated nanoparticle layers. As this technique leverages the nanometer resolution inherent in current magnetic recording technology, strong potential exists for low-cost nanomanufacturing of optical and electronic devices from a variety of nanomaterials with ∼10 nm resolution.