Directed assembly of conducting polymers on sub-micron templates by electrical fields

Patterning of conducting polymer into sub-micron patterns over large areas at high rate and low cost is significant for commercial manufacturing of novel devices. Electrophoretic and dielectrophoretic assembly provide an easily scaled approach with high fabrication rates. In this work, electrophoretic and dielectrophoretic assembly were used to assemble polyaniline (PANi) into multiscale sub-micron size patterns in less than 1 min. The process was controlled by assembly time, amplitude, and frequency of the electric field. Dielectrophoretic assembly is preferable for manufacturing as it reduces damage to the templates used to control the assembly. Using this method, sub-micron patterns with dimensions of the assembled PANi down to 100 nm were fabricated over large areas in short times. The assembled PANi was further transferred to other flexible polymer substrates by a thermoforming process, providing a fast, easily controlled and promising approach for fabrication of nanoscale devices.