Exploiting physical vapor deposition for morphological control in semi-crystalline polymer films

Research in semi-crystalline polymer thin films has seen significant growth due to their fascinating thermal, mechanical, and electronic properties. In all applications, acquiring precise control over the film morphology atop various substrates or in the free-standing film geometry is key to advancing product performance. This article reviews the crystallization of polymer thin films processed via physical vapor deposition (PVD). Classical PVD techniques are briefly reviewed, highlighting their working principles as well as successes and challenges to achieving morphological control of polymer films. Subsequently, the recent development of a unique PVD technique termed Matrix Assisted Pulsed Laser Evaporation (MAPLE) is highlighted. The non-destructive technology overcomes the major drawback of polymer degradation by classical PVD. Recent advances highlighting how MAPLE can be exploited to control polymer film morphology in ways not achievable by other methods are presented. Challenges and future scope of PVD for polymer film deposition concludes the review.