A Strategy for Suppressing Bundling in Dielectrophoretically Assembled Carbon Nanotube Arrays

Densely packed semiconducting carbon nanotube (CNT) arrays with well-controlled morphology are highly desirable for high-performance CNT-based electronics. Although dielectrophoresis (DEP) enables precise, efficient, and site-selective assembly, increasing array density often destabilizes process regulation and aggravates nanotube bundling because of the dynamic interplay among assembly conditions. Here, we introduce the effective deposition region (EDR) to reformulate DEP assembly into a framework that links DEP conditions and final arrays through an interpretable CNT deposition dynamic based on the effective DEP capture. Within this framework, experiments and modeling indicate a self-regulating, negative-feedback mechanism in which conductive CNT bridging reduces the gap voltage, contracts the EDR, and weakens sustained CNT-capture capability, thereby driving the assembly toward self-termination. By synergistically optimizing the applied voltage, electrode configuration, and CNT dispersion concentration to regulate EDR contraction, we obtained dense, bundle-suppressed CNT arrays with the number of nanotubes per unit width of approximately 140 tubes µm−1. The formation of small bundles implies that further combination of EDR-regulated assembly with additional inter-tube interactions is required to realize dense, monolayer CNT arrays. This work provides a coherent mechanistic framework for understanding feedback-regulated DEP assembly and enables a practical approach for optimizing both densification and morphology control in CNT array assembly.