High aspect ratio wrinkles via substrate prestretch

Surface Deformation of Biocompatible Materials: Recent Advances in Biological Applications

The surface topography of substrates is a crucial factor that determines the interaction with biological materials in bioengineering research. Therefore, it is important to appropriately modify the surface topography according to the research purpose. Surface topography can be fabricated in various forms, such as wrinkles, creases, and ridges using surface deformation techniques, which can contribute to the performance enhancement of cell chips, organ chips, and biosensors. This review provides a comprehensive overview of the characteristics of soft, hard, and hybrid substrates used in the bioengineering field and the surface deformation techniques applied to the substrates. Furthermore, this review summarizes the cases of cell-based research and other applications, such as biosensor research, that utilize surface deformation techniques. In cell-based research, various studies have reported optimized cell behavior and differentiation through surface deformation, while, in the biosensor and biofilm fields, performance improvement cases due to surface deformation have been reported. Through these studies, we confirm the contribution of surface deformation techniques to the advancement of the bioengineering field. In the future, it is expected that the application of surface deformation techniques to the real-time interaction analysis between biological materials and dynamically deformable substrates will increase the utilization and importance of these techniques in various fields, including cell research and biosensors.

Coexistence and Coevolution of Wrinkle and Ridge Patterns in the Film-Substrate System by Uniaxial Compression

Homogeneous wrinkles and localized patterns are ubiquitous in nature and are useful for a wide range of practical applications. Although various strain-driven surface instability modes have been extensively investigated in the past decades, understanding the coexistence, coevolution, and interaction of wrinkles and localized patterns is still a great challenge. Here, we report on the formation and evolution of coexisting wrinkle and ridge patterns in metal films deposited on poly(dimethylsiloxane) (PDMS) substrates by uniaxial compression. It is found that the evolving surface patterns show unique features of morphological transition from stages I to III: namely, transition from localized ridges to coexisting wrinkles and ridges, and finally to sinusoidal-like structures, as the compression increases. Based on the compressive strain-driven surface instability theory and finite element numerical simulation, the morphological features, transition behaviors, and underlying mechanisms of such complex patterns are investigated in detail, and the changes of amplitude and wavelength versus the strain are consistent with our experiments. This work could promote a better understanding of the effect of strain localization and the interaction of multiple surface patterns in hard film-soft substrate systems.

Synthesis of Wrinkle-Free Metallic Thin Films in Polymer by Interfacial Instability Suppression with Nanoparticles

Synthesis of a smooth conductive film over an elastomer is vital to the development of flexible optics and wearable electronics, but applications are hindered by wrinkles and cracks in the film. To date, a large-scale wrinkle-free film in an elastomer has yet to be achieved. We present a robust method to fabricate wrinkle-free, stress-free, and optically smooth thin film in elastomer. Targeting underlying mechanisms, we applied nanoparticles between the film and elastomer to jam the interface and subsequently suppress interfacial instabilities to prevent the formation of wrinkles. Using polydimethylsiloxane (PDMS) and parylene-C as a model system, we have synthesized large-scale (>10 cm) wrinkle-free Al film over/in PDMS and demonstrated the principle of interface jamming by nanoparticles. We varied the jammer layer thickness to show that, as the layer exceeds a critical thickness (e.g., 150 nm), wrinkles are successfully suppressed. Nano-indentation experiments revealed that the interface becomes more elastic and less viscoelastic with respect to the jammer thickness, which further supports our assertion of the wrinkle suppression mechanism. Since the film was embedded in a polymer matrix, the resultant film was highly deformable, elastic, and optically smooth with applications for deformable optical sensors and actuators.

Building blocks that govern spontaneous and programmed pattern formation in pre-compressed bilayers

Surface wrinkling in stiff-film/soft-substrate bilayers is a common phenomenon in biological systems and is increasingly being exploited in thin-film technology. While the onset of surface wrinkling in end-compressed bilayers is well understood, questions remain with regards to the evolution of the wrinkling pattern in the intermediate and deep post-wrinkling regimes, especially when the substrate is strongly pre-compressed. Here, we explore the bifurcation landscape of end-compressed bilayers with strongly pre-compressed substrates, using hyperelastic, plane strain finite-elements and generalized path-following algorithms. After bifurcating from a flat into a sinusoidally wrinkled state, bilayers undergo further n -tupling bifurcations into stable wrinkling patterns of longer wavelength whose periodicity n = { 4 , … , 8 } is a function of overall bilayer length. These five n -tupling wrinkling patterns are shown to be independent localizations of the deformation mode and are accordingly identified as stable ‘building blocks’ that govern the intermediate post-wrinkling regime. Additional end-shortening into the deep post-wrinkling regime then leads to further period doubling and coalescence of the building blocks. Beyond a certain length threshold, a bilayer can form a combinatorial side-by-side arrangement of the five building blocks. In the limit of an infinitely long bilayer, this leads to the phenomenon known as spatial chaos with the emergence of an infinite set of possible wrinkling patterns. In reality, though, the precise side-by-side arrangement of the building blocks is governed by the initial conditions. We show that the morphological evolution of the wrinkling pattern can be programmed by a judicial placement of manufactured dents in the thin film, creating new manufacturing capabilities for textured bilayers.

Flexible Sensory Systems: Structural Approaches

Biology is characterized by smooth, elastic, and nonplanar surfaces; as a consequence, soft electronics that enable interfacing with nonplanar surfaces allow applications that could not be achieved with the rigid and integrated circuits that exist today. Here, we review the latest examples of technologies and methods that can replace elasticity through a structural approach; these approaches can modify mechanical properties, thereby improving performance, while maintaining the existing material integrity. Furthermore, an overview of the recent progress in wave/wrinkle, stretchable interconnect, origami/kirigami, crack, nano/micro, and textile structures is provided. Finally, potential applications and expected developments in soft electronics are discussed.

Visualization of nonsingular defect enabling rapid control of structural color

Stimuli-interactive structural color (SC) of a block copolymer (BCP) photonic crystal (PC) uses reversible alteration of the PC using external fluids and applied forces. The origin of the diffusional pathways of a stimulating fluid into a BCP PC has not been examined. Here, we directly visualize the vertically oriented screw dislocations in a one-dimensional lamellar BCP PC that facilitate the rapid response of visible SC. To reveal the diffusional pathway of the solvent via the dislocations, BCP lamellae are swollen with an interpenetrated hydrogel network, allowing fixation of the swollen state and subsequent microscopic examination. The visualized defects are low-energy helicoidal screw dislocations having unique, nonsingular cores. Location and areal density of these dislocations are determined by periodic concentric topographic nanopatterns of the upper surface-reconstructed layer. The nonsingular nature of the interlayer connectivity in the core region demonstrates the beneficial nature of these defects on sensing dynamics.

Ultrasensitive, Stretchable, and Fast-Response Temperature Sensors Based on Hydrogel Films for Wearable Applications

Conductive hydrogels can be used in wearable electronics integrated with skin, but the bulk structure of existing hydrogel-based temperature sensors limits the wearing comfort, response/recovery speeds, and sensitivity. Here, stretchable and transparent temperature sensors based on a novel thin-film sandwich structure (TFSS) are designed, which display unprecedented thermal sensitivity (24.54%/°C), fast response time (0.19 s) and recovery time (0.08 s), a broad detection range (from -28 to 95.3 °C), high resolution (0.8 °C), and high stability. The thin hydrogel layer (12.15 μm) is encapsulated by two thin elastomer layers, which prevent the water evaporation and enhance the heat transfer, leading to the boosted stability and accelerated response/recovery speeds. The nondrying and antifreezing capabilities are further promoted by the hydratable lithium bromide (LiBr) incorporated in the hydrogel, enabling it to avoid dehydration in an extremely arid environment and freeze below subzero temperatures (freezing point below -120 °C). A comparative study reveals that the thermal sensitivity displayed by the TFSS sensor in capacitance mode is several times higher than that in conventional conductance/resistance mode above room temperature. Importantly, a new mechanism based on a horizontal plate capacitance model is proposed to understand the high sensitivity by considering the permittivity and geometry variations of TFSS. The thin TFSS, stretchability and transparency enable the sensor to be conformally and comfortably attached to human skin for real-time and reliable monitoring of various human motions, physical states, skin temperature, etc., without affecting the appearance.

Surface wrinkle formation by liquid crystalline polymers for significant light extraction enhancement on quantum dot light-emitting diodes

We propose an optimal outcoupling structure of a quantum-dot light-emitting diode (QLED) and present material properties based on numerical calculations via the ray-tracing method, in which light extraction properties are obtained according to the surface wrinkles on a substrate. After analyzing the designed microstructure elements, the optimal model was derived and applied to the QLEDs; consequently, the outcoupling efficiency enhanced by 31%. The liquid crystalline polymer forming the random surface wrinkles not only achieves an excellent light extraction through plasma crosslinking but also facilitates large-area processes. We propose an optical design rule for high-efficiency QLED design by analyzing the electro-optical efficiency, emission spectrum, and angular radiation pattern of the optical device.

Bioinspired Multiscale Wrinkling Patterns on Curved Substrates: An Overview

The surface wrinkling of biological tissues is ubiquitous in nature. Accumulating evidence suggests that the mechanical force plays a significant role in shaping the biological morphologies. Controlled wrinkling has been demonstrated to be able to spontaneously form rich multiscale patterns, on either planar or curved surfaces. The surface wrinkling on planar substrates has been investigated thoroughly during the past decades. However, most wrinkling morphologies in nature are based on the curved biological surfaces and the research of controllable patterning on curved substrates still remains weak. The study of wrinkling on curved substrates is critical for understanding the biological growth, developing three-dimensional (3D) or four-dimensional (4D) fabrication techniques, and creating novel topographic patterns. In this review, fundamental wrinkling mechanics and recent advances in both fabrications and applications of the wrinkling patterns on curved substrates are summarized. The mechanics behind the wrinkles is compared between the planar and the curved cases. Beyond the film thickness, modulus ratio, and mismatch strain, the substrate curvature is one more significant parameter controlling the surface wrinkling. Curved substrates can be both solid and hollow with various 3D geometries across multiple length scales. Up to date, the wrinkling morphologies on solid/hollow core-shell spheres and cylinders have been simulated and selectively produced. Emerging applications of the curved topographic patterns have been found in smart wetting surfaces, cell culture interfaces, healthcare materials, and actuators, which may accelerate the development of artificial organs, stimuli-responsive devices, and micro/nano fabrications with higher dimensions.

The emergence of local wrinkling or global buckling in thin freestanding bilayer films

Periodic wrinkling of a rigid capping layer on a deformable substrate provides a useful method for templating surface topography for a variety of novel applications. Many experiments have studied wrinkle formation during the compression of a rigid film on a relatively soft pre-strained elastic substrate, and most have focused on the regime where the substrate thickness can be considered semi-infinite relative to that of the film. As the relative thickness of the substrate is decreased, the bending stiffness of the film dominates, causing the bilayer to transition to either local wrinkling or a global buckling instability. In this work optical microscopy was used to study the critical parameters that determine the emergence of local wrinkling or global buckling of freestanding bilayer films consisting of a thin rigid polymer capping layer on a pre-strained elastomeric substrate. The thickness ratio of the film and substrate as well as the pre-strain were controlled and used to create a buckling phase diagram which describes the behaviour of the system as the ratio of the thickness of the substrate is decreased. A simple force balance model was developed to understand the thickness and strain dependences of the wrinkling and buckling modes, with excellent quantitative agreement being obtained with experiments using only independently measured material parameters.

Harnessing Multiple Surface Deformation Modes for Switchable Conductivity Surfaces

Surface deformation modes, such as wrinkling, creasing, and cracking, enable a plethora of surface morphologies under mechanical loading, which have been widely exploited to provide flexibility and stretchability to electronic devices. As each phenomenon offers a distinct set of potential advantages, controlling the types and spatial locations of deformation modes is key for their successful application. In this study, we demonstrate a method to simultaneously harness multiple surface deformation modes-wrinkles, creases, and cracks-in patterned multilayer films. The wrinkling of metal-coated stiff patterned films provides flexibility and stretchability, while the reversible formation of creases in the intervening regions of the bare elastomer is used to template the formation of patterned cracks in the metal. While conventional cracks can be difficult to precisely control, the patterned cracks demonstrated here remain straight over long distances and show tunable lateral spacings from hundreds of micrometers to centimeters. Finally, the reversible opening and closing of these cracks under mechanical loading provides mechanically gated electrical switches with small and tunable critical switching strains of 0.05-0.18 and high on/off ratios of >10⁷, enabling the preparation of mechanical NAND and NOR logic gates each composed of multiple patterned switches on a single elastomer surface.

Orthogonal wave superposition of wrinkled, plasma-oxidised, polydimethylsiloxane surfaces

We report a versatile approach to generate 2D dual-frequency patterns on soft substrates by superposition of 1D single-frequency wrinkles. Wave superposition is achieved by applying sequential orthogonal strains to elastomeric coupons, as opposed to the application of a (simultaneous) biaxial strain field. First, a 1D wrinkling pattern is induced by the well-known mechanical instability of a bilayer formed by oxygen plasma-oxidation of a (pre-strained) polydimethylsiloxane elastomer. The wrinkled surface formed upon strain release is then replicated to obtain a stress-free substrate, and stretched in the direction perpendicular to the first generation. Subsequent plasma exposure and mechanical relaxation (with independent process parameters) yield a prescribed second-generation wrinkling, whose profile and dependence on the first generation we examine in detail. By independently varying plasma oxidation and strain parameters in both directions, we demonstrate the formation of a wide array of topographies, including arrays of symmetric 2D checkerboard patterns with exceptional area coverage with respect to those formed by simultaneous 2D wrinkling. While the resulting topographies cannot be explained in terms of a simple orthogonal wave superposition, we show that, by accounting for the orthogonal prestrain experienced by the first wrinkling generation, the resulting 2D patterns can be readily calculated from 1D wrinkling behaviour.

All-Optical Reversible Azo-Based Wrinkling Patterns with High Aspect Ratio and Polarization-Independent Orientation for Light-Responsive Soft Photonics

Azobenzene-containing polymers (azopolymers) can serve as building blocks for an emerging class of soft photonics. Using their photoresponses for the micro/nanofabrication of smart surface is a key but still a challenging step. Here, we report a simple visible-light-illumination strategy to trigger diverse configurations of surface wrinkling on azopolymer-based film/substrate systems, which can be switched between flat and wrinkled states by controlling the intensity of the incident light. Different photoresponsive characteristics of azobenzene are involved in driving the wrinkling/dewrinkling switch. For the first time, we achieve the controlled wrinkling with an unexpected high aspect ratio and surprisingly polarization-independent ordered orientation by exploiting the unique photosoftening effect of azobenzene. Theoretical analysis reveals that an in situ photoinduced reversible soft/hard-contrast boundary determines the wrinkling orientation, which is used to fabricate diverse on-demand hierarchical wrinkles. These photoresponsive systems find broad photonic applications that are not easily accessible to other systems, e.g., optically reversible smart display, information security, and well-regulated optical devices.

Highly Flexible, Stretchable, and Tunable Optical Diffusers with Mechanically Switchable Wettability Surfaces

Highly stretchable and super-hydrophobic photonics provides a new geometric degree of freedom for photonic system design and self-cleaning applications. Here, we describe the design and experimental realization of mechanically stretchable and tunable photonic diffusers. These intrinsically designed diffusers (based on periodic arrays of cylindrical lenslets and microtip) were made directly on elastomer material using laser ablation. The dimensions of both the tips and the lenslet arrays play a critical role in the distribution of illumination and wettability resistance. By stretching the diffusers mechanically along the lenslet arrays, diffusion angle tuning was achieved and also a reversible change between hydrophilic to super-hydrophobic states. These multifunctional diffusers constitute an important step toward integration with flexible materials or devices such as stretchable organic light-emitting diodes and polymer light-emitting diodes.

Multilayer Polypyrrole Nanosheets with Self-Organized Surface Structures for Flexible and Efficient Solar-Thermal Energy Conversion

Converting solar energy into concentrated heat is very appealing for various applications. Polypyrrole (PPy) is known to possess excellent photothermal property with low thermal conductivity, and thus is an ideal candidate for solar-thermal energy conversion. However, solar-thermal materials based on PPy or other conducting polymers still exhibit limited energy conversion efficiency due to the lack of effective light-trapping schemes. Here, it is demonstrated that multilayer PPy nanosheets with spontaneously formed surface structures such as wrinkles and ridges via sequential polymerization on paper substrates can dramatically enhance broadband and wide-angle light absorption across the full solar spectrum, leading to an impressive solar-thermal conversion efficiency of 95.33%. The intriguing solar-thermal properties and structural features of multilayer PPy nanosheets can be used for solar heating and photoactuators. Meanwhile, when used for solar steam generation, the measured efficiency could achieve ≈92% under one sun irradiation. The hierarchically multilayer structure is mechanically flexible and robust, holding great potential for practical solar energy utilization. This study provides a simple and straightforward approach toward engineering light-weight and thermally insulating polymers into efficient solar-thermal materials for emerging solar energy-related applications.

Wrinkling of two-dimensional materials: methods, properties and applications

Recently, two-dimensional (2D) materials, including graphene, its derivatives, metal films, MXenes and transition metal dichalcogenides (TMDs), have been widely studied because of their tunable electronic structures and special electrical and optical properties. However, during the fabrication of these 2D materials with atomic thickness, formation of wrinkles or folds is unavoidable to enable their stable existence. Meaningfully, it is found that wrinkled structures simultaneously impose positive changes on the 2D materials. Specifically, the architecture of wrinkled structures in 2D materials additionally induces excellent properties, which are of great importance for their practical applications. In this review, we provide an overview of categories of 2D materials, which contains formation and fabrication methods of wrinkled patterns and relevant mechanisms, as well as the induced mechanical, electrical, thermal and optical properties. Furthermore, these properties are modifiable by controlling the surface topography or even by dynamically stretching the 2D materials. Wrinkling offers a platform for 2D materials to be applied in some promising fields such as field emitters, energy containers and suppliers, field effect transistors, hydrophobic surfaces, sensors for flexible electronics and artificial intelligence. Finally, the opportunities and challenges of wrinkled 2D materials in the near future are discussed.

Relationship between Hydrogen Evolution and Wettability for Multiscale Hierarchical Wrinkles

Transition metal dichalcogenides (TMDs) are emerging two-dimensional materials with potential use for the hydrogen evolution reaction (HER) because they express a desired binding energy with protons. To date, TMD-based HER catalytic performance has been enhanced mostly by chemical modification, such as introducing defects, doping, and phase control. Herein, we enhanced the HER performance by precise control of wettability via hierarchical wrinkling. This hierarchical wrinkling confers tunability of the receding contact angle (2-30°) by controlling the wavelength of the hierarchical wrinkles. Minimization of the receding contact angle is directly related to overpotential reduction on the MoS₂ wrinkles through gas detachment from the catalytic surface. Unlike in previous studies, in this work, we demonstrated the effect of wettability only without changing other parameters such as surface chemistry. We showed that our method can be applied to other TMD materials such as WS₂. This study will contribute to future TMD-based catalyst applications, such as hydrogen evolution, CO₂ reduction, and oxygen evolution.

Materials and Structures toward Soft Electronics

Soft electronics are intensively studied as the integration of electronics with dynamic nonplanar surfaces has become necessary. Here, a discussion of the strategies in materials innovation and structural design to build soft electronic devices and systems is provided. For each strategy, the presentation focuses on the fundamental materials science and mechanics, and example device applications are highlighted where possible. Finally, perspectives on the key challenges and future directions of this field are presented.

Formation of high aspect ratio wrinkles and ridges on elastic bilayers with small thickness contrast

An elastic bilayer composed of a stiff film bonded to a soft substrate forms wrinkles under compression. While these uniform and periodic wrinkles initially grow in amplitude with applied strain, the onset of secondary bifurcations such as period doubling typically limit the aspect ratio (i.e., amplitude divided by wavelength) of wrinkles that can be achieved. Here, we present a simple strategy that employs a supported bilayer with comparable thicknesses of the film and substrate to achieve wrinkles with higher aspect ratio. We use both experiments and finite element simulations to reveal that at small thickness contrast, period doubling can be delayed, allowing the wrinkles to grow uniformly to high aspect ratio. In addition, we show that the periodic wrinkles can evolve through symmetry breaking and transition to a periodic pattern of ridges with even higher aspect ratio.

Folding artificial mucosa with cell-laden hydrogels guided by mechanics models

The surfaces of many hollow or tubular tissues/organs in our respiratory, gastrointestinal, and urogenital tracts are covered by mucosa with folded patterns. The patterns are induced by mechanical instability of the mucosa under compression due to constrained growth. Recapitulating this folding process in vitro will facilitate the understanding and engineering of mucosa in various tissues/organs. However, scant attention has been paid to address the challenge of reproducing mucosal folding. Here we mimic the mucosal folding process using a cell-laden hydrogel film attached to a prestretched tough-hydrogel substrate. The cell-laden hydrogel constitutes a human epithelial cell lining on stromal component to recapitulate the physiological feature of a mucosa. Relaxation of the prestretched tough-hydrogel substrate applies compressive strains on the cell-laden hydrogel film, which undergoes mechanical instability and evolves into morphological patterns. We predict the conditions for mucosal folding as well as the morphology of and strain in the folded artificial mucosa using a combination of theory and simulation. The work not only provides a simple method to fold artificial mucosa but also demonstrates a paradigm in tissue engineering via harnessing mechanical instabilities guided by quantitative mechanics models.

Harmonic analysis of surface instability patterns on colloidal particles

Wrinkling of colloidal particles alter a wide variety of interfacial properties but quantitative topographical descriptions have been explored experimentally to a very limited extent. In this study, we present a harmonic analysis of surface wrinkles and folds on submicron colloidal particles, obtained using an aerosol flow route, with small radius (<300 nm) and high crust thickness-to-radius ratio (>0.1). The particle surface coordinates were mapped in their entirety using cryo-electron tomography and subsequently reconstructed using spherical harmonics, allowing a spectral topographical description of the instability patterns and the identification of their surface modes by lateral wavelength. Wrinkled and crumpled particles showed a similar surface roughness spectrum, wherein differences were found most noticeable in the large wavelength region. The analysis of preferred directions of harmonic frequencies indicated a possible axial or planar alignment attributed to the directionality of the surface corrugations. The employed characterization methodology can further the study of topographical influences on colloidal interactions.

Buckling patterns in biaxially pre-stretched bilayer shells: wrinkles, creases, folds and fracture-like ridges

We introduce a new experimental system to study the effects of pre-stretch on the buckling patterns that emerge from the biaxial compression of elastomeric bilayer shells. Upon fabrication of the samples, releasing the pre-stretch in the substrate through deflation places the outer film in a state of biaxial compression and yields a variety of buckling patterns. We systematically explore the parameter space by varying the pre-stretch of the substrate and the ratio between the stiffness of the substrate and film. The phase diagram of the system exhibits a variety of buckling patterns: from the classic periodic wrinkle to creases, folds, and high aspect ratio ridges. Our system is capable of readily transitioning between these buckling patterns, a first for biaxial systems. We focus on the wrinkle to ridge transition. In the latter, we find that pre-stretch plays an essential role and that the ridge geometry (width, height) remains nearly constant throughout their formation process. For the localized ridged patterns, we find that the propagation of the ridge tip depends strongly on both strain and stiffness ratio, in a way that is akin to hierarchical fracture.

Transition of surface-interface creasing in bilayer hydrogels

Controlling the morphologies and properties of the surface and/or interface of bimaterials consisting of soft polymers provides new opportunities in many engineering applications. Crease is a widely observed deformation mode in nature and engineering applications for soft polymers where the smooth surface folds into a region of self-contact with a sharp tip, usually induced by the instability from mechanical compression or swelling. In this work, we explore the competition mechanisms between surface and interface creases through numerical simulations and experimental studies on bilayer hydrogels. The surface or interface crease of the bilayer hydrogels under swelling is governed by both the modulus ratio (M₂/M₁) and the height ratio (H₂/H₁). Through extensive numerical simulations, we find that the interface crease of the bilayer hydrogels can only occur at a moderate modulus ratio (24 < M₂/M₁ < 96) and a large height ratio (H₂/H₁ ≥ 8). Guided by this phase diagram, our experiments confirm that both surface and interface creases can be generated by swelling triggered instability, and the transition of surface to interface creases occurs at the critical value of the height ratio (H₂/H₁) between 5 and 10. Such an observation is in good agreement with our numerical predictions. Fundamental understandings on the switching between the surface and interface creases provide new insights into the design of highly tunable soft materials and devices over a wide range of length scales.

Formation of a Crack-Free, Hybrid Skin Layer with Tunable Surface Topography and Improved Gas Permeation Selectivity on Elastomers Using Gel-Liquid Infiltration Polymerization

Surface modifications of elastomers and gels are crucial for emerging applications such as soft robotics and flexible electronics, in large part because they provide a platform to control wettability, adhesion, and permeability. Current surface modification methods via ultraviolet-ozone (UVO) and/or O₂ plasma, atomic layer deposition (ALD), plasmas deposition, and chemical treatment impart a dense polymer or inorganic layer on the surface that is brittle and easy to fracture at low strain levels. This paper presents a new method, based on gel-liquid infiltration polymerization, to form hybrid skin layers atop elastomers. The method is unique in that it allows for control of the skin layer topography, with tunable feature sizes and aspect ratios as high as 1.8 without fracture. Unlike previous techniques, the skin layer formed here dramatically improves the barrier properties of the elastomer, while preserving skin layer flexibility. Moreover, the method is versatile and likely applicable to most interfacial polymerization systems and network polymers on flat and patterned surfaces.

Achieving high aspect ratio wrinkles by modifying material network stress

Wrinkle aspect ratio, or the amplitude divided by the wavelength, is hindered by strain localization transitions when an increasing global compressive stress is applied to synthetic material systems. However, many examples from living organisms show extremely high aspect ratios, such as gut villi and flower petals. We use three experimental approaches to demonstrate that these high aspect ratio structures can be achieved by modifying the network stress in the wrinkle substrate. We modify the wrinkle stress and effectively delay the strain localization transition, such as folding, to larger aspect ratios by using a zero-stress initial wavy substrate, creating a secondary network with post-curing, or using chemical stress relaxation materials. A wrinkle aspect ratio as high as 0.85, almost three times higher than common values of synthetic wrinkles, is achieved, and a quantitative framework is presented to provide understanding the different strategies and predictions for future investigations.

Stretching-induced wrinkling in plastic-rubber composites

We examine the mechanics of three-layer composite films composed of an elastomeric layer sandwiched between two thin surface layers of plastic. Upon stretching and releasing such composite films, they develop a highly wrinkled surface texture. The mechanism for this texturing is that during stretching, the plastic layers yield and stretch irreversibly whereas the elastomer stretches reversibly. Thus upon releasing, the plastic layers buckle due to compressive stress imposed by the elastomer. Experiments are conducted using SEPS elastomer and 50 micron thick LLDPE plastic films. Stretching and releasing the composites to 2-5 times their original length induces buckles with wavelength on the order of 200 microns, and the wavelength decreases as the stretching increases. FEM simulations reveal that plastic deformation is involved at all stages during this process: (1) during stretching, the plastic layer yields in tension; (2) during recovery, the plastic layer first yields in-plane in compression and then buckles; (3) post-buckling, plastic hinges are formed at high-curvature regions. Homogeneous wrinkles are predicted only within a finite window of material properties: if the yield stress is too low, the plastic layers yield in-plane, without wrinkling, whereas if the yield stress is too high, non-homogeneous wrinkles are predicted. This approach to realizing highly wrinkled textures offers several advantages, most importantly the fact that high aspect ratio wrinkles (amplitude to wavelength ratios exceeding 0.4) can be realized.

High-Aspect-Ratio Ridge Structures Induced by Plastic Deformation as a Novel Microfabrication Technique

Wrinkles on thin film/elastomer bilayer systems provide functional surfaces. The aspect ratio of these wrinkles is critical to their functionality. Much effort has been dedicated to creating high-aspect-ratio structures on the surface of bilayer systems. A highly prestretched elastomer attached to a thin film has recently been shown to form a high-aspect-ratio structure, called a ridge structure, due to a large strain induced in the elastomer. However, the prestretch requirements of the elastomer during thin film attachment are not compatible with conventional thin film deposition methods, such as spin coating, dip coating, and chemical vapor deposition (CVD). Thus, the fabrication method is complex, and ridge structure formation is limited to planar surfaces. This paper presents a new and simple method for constructing ridge structures on a nonplanar surface using a plastic thin film/elastomer bilayer system. A plastic thin film is attached to a stress-free elastomer, and the resulting bilayer system is highly stretched one- or two-dimensionally. Upon the release of the stretch load, the deformation of the elastomer is reversible, while the plastically deformed thin film stays elongated. The combination of the length mismatch and the large strain induced in the elastomer generates ridge structures. The morphology of the plastic thin film/elastomer bilayer system is experimentally studied by varying the physical parameters, and the functionality and the applicability to a nonplanar surface are demonstrated. Finally, we simulate the effect of plasticity on morphology. This study presents a new technique for generating microscale high-aspect-ratio structures and its potential for functional surfaces.

The formation and control of highly crumpled metal surfaces on a photocurable viscous liquid

Folds, highly deformed structures, have received extensive attention for their nonlinear responses due to a large strain on soft matters. To investigate the folding phenomena, here, we exploit residual tensile stress during metal deposition, which is large enough to compress a thin film coating and introduce a photocurable viscous fluid to decrease the resistance of the substrate against compressive stress. The system has the advantages of the abilities for freezing the highly deformed surfaces by post-UV exposure to the UV-crosslinkable substrate and manipulating the substrate effect by controlling the thickness of the substrate. We theoretically investigated the dependence on the substrate thickness using scaling analysis and demonstrated self-generated ladder and flower-like graphoepitaxial structures originated from the thickness design of the viscous substrate.

Wrinkling Measurement of the Mechanical Properties of Drying Salt Thin Films

We report a time-resolved approach to probe the mechanical properties of thin films during drying and solidification based on surface wrinkling. The approach is demonstrated by measuring the modulus of a ternary system comprising an inorganic salt (aluminum chlorohydrate), a humectant (glycerol), and water across the glassy film formation pathway. The topography of mechanically induced wrinkling of supported films on polydimethylsiloxane (PDMS) is experimentally monitored during mechanical extension and relaxation cycles. Nontrivial aspects of our method include the need to oxidize the (hydrophobic) PDMS surface prior to solution deposition to enable surface wetting, which simultaneously creates a glassy-layer skin, whose wrinkling can contribute to the overall topography. Film drying is studied as a function of solution concentration and time, and a range of pattern morphologies are found: sinusoidal wrinkling, transient double-wavelength wrinkling accompanying film "crust" formation, ridging associated with stress localization, and cracking. We quantify the evolution of the elastic modulus during the sinusoidal wrinkling stage, employing bi- and trilayer models, which are independently confirmed by nanoindentation. The method provides thus a simple and robust approach for the mechanical characterization of out-of-equilibrium thin films.

Controlled Formation of Surface Patterns in Metal Films Deposited on Elasticity-Gradient PDMS Substrates

Controlled surface patterns are useful in a wide range of applications including flexible electronics, elastomeric optics, fluidic channels, surface engineering, measurement technique, biological templates, stamps, and sensors. In this work, we report on the controlled formation of surface patterns in metal films deposited on elasticity-gradient polydimethylsiloxane (PDMS) substrates. Because of the temperature gradient during the curing process, the PDMS substrate in each sample successively changes from a purely liquid state at one side to a purely elastic state at the opposite side. It is found that surface folds appear in the liquid or viscous PDMS region while wrinkles form in the elastic region. In the transition region from the liquid to elastic PDMS, a nested pattern (i.e., the coexisting of folds and wrinkles) can be observed. The folding wave is triggered by the intrinsic stress during the film deposition and its wavelength is independent of the film thickness. The wrinkling wave is induced by the thermal compression after deposition and its wavelength is proportional to the film thickness. The report in this work could promote better understanding of the effect of substrate elasticity on the surface patterns and fabrication of such patterns (folds and wrinkles) by tuning the substrate property.

Bloch wave approach for the analysis of sequential bifurcations in bilayer structures

A wide variety of surface morphologies can be formed by compressing a bilayer comprising a thin film bonded to a compliant substrate. In particular, as the applied strain is increased, secondary instabilities are triggered and the initial sinusoidal wrinkles evolve into new complex patterns. Here, we propose a robust numerical analysis based on Floquet–Bloch boundary conditions to detect the primary and secondary instabilities triggered upon compression. Because the proposed method is based on unit cell simulations, it is computationally very efficient. Moreover, it accurately predicts not only the critical strains, but also the corresponding critical modes and their wavelengths, enabling us to follow the evolution of the surface morphology as the applied strain is progressively increased.

Controlling and prevention of surface wrinkling via size-dependent critical wrinkling strain

Surface wrinkling may occur in a film-substrate system when the applied strain exceeds the critical value. However, the practically required strain for the onset of surface wrinkling can be different from the theoretically predicted value. Here we investigate the film size effect-dependent critical strain for the mechanical strain-induced surface wrinkling via a combination of experiments and theoretical analysis. In the poly(dimethylsiloxane)-based system fabricated by the smart combination of mechanical straining and selective O2 plasma (OP) exposure through Cu grids, the film size effect on the critical wrinkling strain is systematically studied by considering OP exposure duration, the mesh number and geometry of Cu grids. Meanwhile, a simple analytical solution revealing the film size effect is well established, which shows good consistency with the experimental results. This study provides an experimental and theoretical basis for finely tuning the critical wrinkling strain in a simple and quantitative manner, which can find a wide range of applications in such fields as microelectronic circuits and optical devices, where controlling and/or prevention of surface wrinkling are of great importance.

Wrinkled stripes localized by cracks in metal films deposited on soft substrates

Homogeneous global wrinkling patterns such as labyrinths, herringbones, ripples and straight stripes can be widely observed in natural and artificial systems, but localized wrinkling patterns (not including buckle-driven delaminations, folds, ridges and creases) are seldom observed in experiments. Here we report on the spontaneous formation of highly ordered wrinkled stripes localized by cracks in metal films deposited on soft substrates. The experiment shows that the metal film is under a large tensile stress during deposition, which is relieved by the formation of networked cracks. After deposition, a compressive stress is stored up in the film and it always focuses near the new formed cracks due to the plastic deformation of the film, resulting in the formation of localized wrinkled stripes composed of a large number of straight wrinkles perpendicular to the cracks. The morphological characteristic, formation mechanism and evolution behaviors of the localized wrinkled stripes have been described and discussed in detail.

Folding and birefringence behavior of poly(vinyl alcohol) hydrogel film induced by freezing and thawing

A band-like folding structure with high aspect ratio, parallel or perpendicular to the flat film, and birefringence behavior was observed for an in situ formed thin PVA hydrogel film, the folding structure being formed via freezing–thawing treatment of PVA aqueous solution coated on glass.