In a manner reminiscent of macroscale bending and folding techniques such as origami, the out-of-plane assembly of lithographically micro- and nanopatterned thin films, can be used to fabricate three-dimensional (3D) micro- and nanostructured devices. These 3D devices, including microelectronic circuits, sensors, antennas, metamaterials, robotic, and biomimetic constructs, enable new functionalities and are challenging to fabricate by other methods. In this article, we summarize important features of this set of techniques and the devices assembled thereof, with a focus on functional constructs that have been formed by bending, folding, or buckling. At small size scales, manipulation using manual or even wired probes face daunting practical challenges in terms of cost, scalability, and high-throughput manufacturability; hence we emphasize techniques that manipulate strain in thin films so that they can spontaneously assemble into programmed 3D geometries without the need for any wires or probes.

Block copolymers (BCPs) microphase-separate to form periodic patterns with periods of a few nanometers and above without the need for lithographic guidance. These self-assembled nanostructures have a variety of bulk geometries, including alternating lamellae, gyroids, arrays of cylinders or spheres, tiling patterns and core–shell structures, depending on the molecular architecture of the polymer and the volume fraction of its blocks. Non-bulk morphologies can be produced, the ordering of the microdomains can be improved, and their locations can be directed using various templates and processing strategies. The blocks themselves can constitute a functional material, such as a photonic crystal, or they can be used as a mask to pattern other functional materials, functionalized directly by various chemical approaches, or used as a scaffold to assemble nanoparticles or other nanostructures. BCPs offer tremendous flexibility in creating nanostructured materials with a range of applications in microelectronics, photovoltaics, filtration membranes, and other devices.

Conventional photolithography is an effective patterning technique that has enabled modern electronics and advanced micro- and nanoscale devices. However, it has limitations, including high cost, limited resolution, and poor compatibility with unconventional materials that may be soft, nonplanar, or difficult to process. There is active research ongoing to develop unconventional patterning methods such as self-organization and self-folding. Self-organization harnesses various driving forces to produce patterns without external intervention and includes methods such as self-assembly of block copolymers, capillary-driven assembly of micro-/nanoscale structures, and thin-film instabilities. Self-folding (origami)—and its cousin, kirigami—harnesses patterning and materials strategies to convert planar substrates into three-dimensional shapes in response to external stimuli. These multidisciplinary approaches open many engineering opportunities by providing new and versatile material functionalities. This article overviews the field and the topics covered in the articles in this issue of MRS Bulletin, highlighting recent progress in patterning approaches based on self-organization and self-folding.

The refinement mechanism of alternating current pulse (ACP) on the solidification macrostructures of pure Al and the characterization of refining efficiency were investigated by embedding the wire mesh in the mold. The experiment results showed that ACP treatment during solidification led to the formation of fine equiaxed grain. There were remarkably differences with respect to the area of fine equiaxed zone inside and outside the tube. Lorentz force, induced melt flow and the rest of intrinsic effects of ACP inside and outside the tube were discussed in the present study. It demonstrated that the forced melt flow could lead to the columnar fragmentation and make the crystal nucleus on the mold wall fall off and drift in the liquid, leading to grain refinement. In addition, Reynolds number was suitable to characterize the refining efficiency of pure Al under ACP.

Nanoparticles are ubiquitous in both natural and synthetic environments, providing much of the chemical reactivity for geochemical, planetary, environmental, and technological processes. However, this reactivity and differences between the bulk and nanoscale are thermodynamically, as well as kinetically, controlled. Energetic effects arising from differences in surface energies of different nanomaterials lead to changes in which phases are thermodynamically stable under given conditions. This results in crossovers in polymorphic stability as a function of particle size and substantial shifts in the positions of dehydration and redox equilibria. Examples of these phenomena in aluminum, cobalt, iron, and manganese oxides are presented, and implications for catalysts, battery materials, and other functional oxides are discussed. A hypothesis is presented that low surface energy and the resulting relatively weak water binding on the surface leads to better function when electrons or ions are transferred at the solid-solution interface.

We present a comprehensive nanoscale tribological characterization of single-layer graphene grown by chemical vapor deposition (CVD) and transferred onto silicon oxide (SiO2) substrates. Specifically, the nanotribological properties of graphene samples are studied via atomic force microscopy (AFM) under ambient conditions using calibrated probes, by measuring the evolution of friction force with increasing normal load. The effect of using different probes and post-transfer cleaning procedures on frictional behavior is evaluated. A new method of quantifying lubrication performance based on measured friction coefficient ratios of graphene and SiO2 is introduced. A comparison of lubrication properties with mechanically-exfoliated graphene is performed. Results indicate that CVD-grown graphene constitutes a very good solid lubricant on SiO2, reducing friction coefficients by ∼90% for all investigated samples. Finally, the effect of wrinkles associated with CVD-grown graphene on measured friction values is quantitatively analyzed, with results revealing a substantial increase in friction on these structural defects.