A high-quality and -throughput colloidal lithography by mechanical assembly and ice-based transfer

Colloidal lithography has emerged as a promising alternative to conventional nanofabrication techniques, offering the ability to create nanoscale patterns in a cost-effective and scalable manner. However, it has been so far limited by defects such as empty areas or multilayered regions, hindering its application. We introduce a novel "ice-assisted transfer" technique that combines rubbing-based particle assembly on elastomer substrates with ice-mediated transfer to achieve defect-free, high-quality polycrystalline particle monolayers. This approach eliminates foreign material contamination and enables precise control of particle arrangement and density. By optimizing process parameters, including surfactant concentration and water film thickness, we minimized defects and demonstrated the versatility of this method in fabricating functional nanoscale structures. We highlighted the benefits of this process through two applications: (1) antireflective "moth-eye" coatings, which achieved near-zero reflection in the mid-infrared spectrum due to improved particle monolayer quality; and (2) nanostructured surfaces for ligand-free T-cell activation, whose topography enhanced cell activation, showcasing potential for immunotherapy applications. The process achieves rapid, cost-efficient patterning without requiring specialized equipment, making it suitable for diverse fields requiring scalable nanostructuring. This work represents a significant advancement in colloidal lithography, addressing critical challenges and unlocking its potential for practical applications in optics, biotechnology, and beyond.