Large-Scale Manufacturing of Functionally-Encoded Semiconductor Nanowires for Electronics and Photonics

Semiconductor nanowires can be produced with exquisite spatial control of composition and morphology using the vapor-liquid-solid (VLS) mechanism. This capability has permitted, for example, demonstrations of transistors, photodetectors, solar cells, and biosensors. Central to our process is the use of sacrificial, porous-walled, seed particle-lined silica microcapsules, whose interior surface serves as a high-surface area growth substrate. These microcapsules protect the growing nanostructures, are produced with a scalable emulsion templating technique, and are compatible with large-scale chemical reactors. We will show how microcapsule structure and drying is influenced by silica nanoparticle type and concentration, emulsification parameters, and nanoparticle cross-linking agent. We will also demonstrate the synthesis of Si nanowires with axially-programmed dopant profiles on the microcapsule interior.