Ultra-Broadband Solar Absorption Enabled by 3D Crown-like Aluminum Nanostructure Arrays

Plasmonic nanostructures offer a practical solution for solar-to-thermal conversion, yet simultaneously achieving ultra-broadband absorption, scalable fabrication, and long-term stability using earth-abundant aluminum remains difficult. In this work, we present a three-dimensional (3D) crown-like aluminum nanostructure absorber that achieves an experimental average absorption of 92% across the solar spectrum (200–2500 nm), with only 1.9% degradation in average absorption over 24 months. The structure is fabricated via a scalable anodic aluminum oxide (AAO) template-assisted method, enabling large-area production without costly lithography and exhibiting broad fabrication tolerance to deposition-thickness variations. Electromagnetic simulations and structure analysis reveal that the ultra-broadband absorption arises from three synergistic mechanisms: multi-mode electric resonances, magnetic resonance behavior within the metal–dielectric–metal architecture, and a graded-refractive-index profile. Proof-of-concept photothermal experiments under simulated sunlight offer experimental confirmation of the absorber’s solar-to-thermal conversion capability, showing substantially enhanced solar-to-thermal energy utilization compared to pure-water references. This work provides a scalable, durable, and cost-effective platform for ultra-broadband solar absorption and solar-to-thermal conversion, and offers a viable design strategy for plasmonic absorbers based on earth-abundant materials.