Fabrication of a Au–polystyrene sphere substrate with three-dimensional nanofeatures for surface-enhanced Raman spectroscopy

Abstract Methods for fabricating three-dimensional nanofeature arrays for surface-enhanced Raman spectroscopy (SERS) substrates were explored by combining the self-assembly of nanoscale polystyrene (PS) spheres with subsequent Au film ion sputter coating modulation. The substrate's nanoscale hot-spot features were controlled using the Au coating film thickness regulation and focused ion beam (FIB) nano-patterning regulation methods. Scanning electron microscopy and Raman spectroscopy were employed to analyze the substrate morphology and the enhancement mechanism of the three-dimensional SERS substrate. PS microspheres with diameters of 151 nm and 360 nm were coated with Au layers of different thicknesses ranging from 10 nm to 270 nm. The configuration of the Au–PS spheres can be regulated to hexagonal close packing with nanoscale V-shaped slits with a 10–20 nm gap pattern. Nanoscale Au particles and clusters with a clear outline covered the surface of the PS spheres, in which the multiple-scale structures increase the specific surface area of the SERS-active substrate. Nanoscale cracks formed on the smaller Au–PS spheres with a diameter of 151 nm, which also exhibited strong SERS activity. The substrate surface temperature regularly increased after Au coating, and the thermal expansion coefficient difference and PS glass transition properties were studied to explain the Au–PS spheres nanofeature configuration development. The fabricated Au–PS spheres SERS feature is a type of three-dimensional and highly ordered array, which can show Raman scattering characteristics by providing a SERS enhancement factor of greater than 107.