Scalable Macroscopic Engineering from Polymer-Based Nanoscale Building Blocks: Existing Challenges and Emerging Opportunities

Natural materials exhibit exceptional properties due to their hierarchical structures spanning from the nano- to the macroscale. Replicating these intricate spatial arrangements in synthetic materials presents a significant challenge as it requires precise control of nanometric features within large-scale structures. Addressing this challenge depends on developing methods that integrate assembly techniques across multiple length scales to construct multiscale-structured synthetic materials in practical, bulk forms. Polymers and polymer–hybrid nanoparticles, with their tunable composition and structural versatility, are promising candidates for creating hierarchically organized materials. This review highlights advances in scalable techniques for nanoscale organization of polymer-based building blocks within macroscopic structures, including block copolymer self-assembly with additive manufacturing, polymer brush nanoparticles capable of self-assembling into larger, ordered structures, and direct-write colloidal assembly. These techniques offer promising pathways toward the scalable fabrication of materials with emergent properties suited for advanced applications such as bioelectronic interfaces, artificial muscles, and other biomaterials.