Abstract
There is a longstanding challenge to disperse metal nanoparticles uniformly in bulk polymers for widespread applications. Conventional scale-down techniques often are only able to shrink larger elements (such as microparticles and microfibers) into micro/nano-elements (i.e. nanoparticles and nanofibers) without much altering their relative spatial and size distributions. Here we show an unusual phenomenon that tin (Sn) microparticles with both poor size distribution and spatial dispersion were stretched into uniformly dispersed and sized Sn nanoparticles in polyethersulfone (PES) through a stack and draw technique in thermal drawing. It is believed that the capillary instability plays a crucial role during thermal drawing. This novel, inexpensive, and scalable method overcomes the longstanding challenge to produce bulk polymer-metal nanocomposites (PMNCs) with a uniform dispersion of metallic nano-elements.