Wafer-Scale Fabrication of Hierarchically Porous Silicon and Silica Glass by Active Nanoparticle-Assisted Chemical Etching and Pseudomorphic Thermal Oxidation

TL;DR

This paper introduces a scalable method combining metal-assisted chemical etching and photolithography to create hierarchically porous silicon and silica with multiscale pores, suitable for energy, sensing, and photonic applications.

Contribution

It presents a novel, scalable fabrication process for hierarchically porous silicon and silica with bimodal pore distribution using self-organized etching and photolithography.

Findings

Successfully fabricated silicon with bimodal porosity including macropores and mesopores.

Demonstrated structure preservation during thermal oxidation to silica.

High-resolution imaging confirmed large open porosity and inner surface area.

Abstract

Many biological materials exhibit a multiscale porosity with small, mostly nanoscale pores as well as large, macroscopic capillaries to simultaneously achieve optimized mass transport capabilities and lightweight structures with large inner surfaces. Realizing such a hierarchical porosity in artificial materials necessitates often sophisticated and expensive top-down processing that limits scalability. Here we present an approach that combines self-organized porosity based on metal-assisted chemical etching (MACE) with photolithographically induced macroporosity for the synthesis of single-crystalline silicon with a bimodal pore-size distribution, i.e., hexagonally arranged cylindrical macropores with 1 micrometer diameter separated by walls that are traversed by mesopores 60 nm across. The MACE process is mainly guided by a metal-catalyzed reduction-oxidation reaction, where silver nanoparticles (AgNPs) serve as the catalyst. In this process, the AgNPs act as self-propelled particles that are constantly removing silicon along their trajectories. High-resolution X-ray imaging and electron tomography reveal a resulting large open porosity and inner surface for potential applications in high-performance energy storage, harvesting and conversion or for on-chip sensorics and actuorics. Finally, the hierarchically porous silicon membranes can be transformed structure-conserving by thermal oxidation into hierarchically porous amorphous silica, a material that could be of particular interest for opto-fluidic and (bio-)photonic applications due to its multiscale artificial vascularization.