Au nanodisks-based 2D photonic crystals fabricated by single-beam laser interference lithography: A simple and reliable alternative for highly efficient large-scale SERS molecular sensors

Noble metal-based Photonic Crystals (PCs) have emerged as outstanding candidates for precise light management, projecting applications in strategic areas for society like high-sensitivity and fast molecular (inorganic/organic/bio) sensing by Surface-Enhanced Raman Spectroscopy (SERS). In this work, we report an exhaustive study on the potential of large-scale (active area >1 [cm2]) Au nanodisks-based 2D PCs fabricated by single-beam Laser Interference Lithography (LIL) for high-performance SERS molecular sensing. This technique was used to fabricate periodic nanoarrays (period of 470 [nm]) of Au nanodisks with thicknesses from 50 up to 125 [nm]. The period was chosen following Finite-Difference Time-Domain (FDTD) simulations that suggested the best electric-near field enhancement for this condition. Confocal Raman microscopy and Methylene Blue (MB) as active Raman marker, were used to assess the samples' performance for molecular sensing. SERS studies have shown that the nanodisks' thickness can be a considerable size parameter for the Raman signal amplification, observing higher signal enhancements for higher thicknesses. The observed thickness effects on the Raman signal enhancement were consistent with FDTD simulations, which predicted higher electric-near field amplifications for higher thickness within the red/near-infrared range. Results show that our PCs enable to measure the characteristic Raman footprint of the analyte with good spectral resolution using relatively low powers (0.04–1 [mW]) and short acquisition times (1–30 [s]), considering an MB surface mass density as low as 2.6 [ng/cm2]. SERS enhancement factors as high as 2 x 107 were achieved for PCs with the highest thickness, representing a competitive performance concerning typically reported values (104–107) for current noble metal-based PCs technologies and a new record concerning PCs fabricated by LIL (104–105). This research demonstrates the high competitivity of these simple Au nanodisks-based 2D PCs, fabricated using an efficient large-scale and low-cost lithography technique, for fast, high spectral resolution and highly reproducible SERS-based molecular sensing.