Adhesion design maps for fibrillar adhesives: the effect of shape

Gecko-Inspired Controllable Adhesive: Structure, Fabrication, and Application

The gecko can achieve flexible climbing on various vertical walls and even ceilings, which is closely related to its unique foot adhesion system. In the past two decades, the mechanism of the gecko adhesion system has been studied in-depth, and a verity of gecko-inspired adhesives have been proposed. In addition to its strong adhesion, its easy detachment is also the key to achieving efficient climbing locomotion for geckos. A similar controllable adhesion characteristic is also key to the research into artificial gecko-inspired adhesives. In this paper, the structures, fabrication methods, and applications of gecko-inspired controllable adhesives are summarized for future reference in adhesive development. Firstly, the controllable adhesion mechanism of geckos is introduced. Then, the control mechanism, adhesion performance, and preparation methods of gecko-inspired controllable adhesives are described. Subsequently, various successful applications of gecko-inspired controllable adhesives are presented. Finally, future challenges and opportunities to develop gecko-inspired controllable adhesive are presented.

Bio-inspired switchable soft adhesion for the boost of adhesive surfaces and robotics applications: A brief review

In nature, millions of creatures, such as geckos, tree frogs, octopuses, etc., have evolved fantastic switchable adhesion capabilities to climb swiftly on vertical even inverted surfaces or hunt for prey easily, adapting to harsh and unpredictable environments. Notably, these fascinating adhesive behaviors depend on interfacial forces (friction, van der Waals force, capillary force, vacuum suction, etc.), which primarily originate from the interactions between the soft micro/nanostructures evolved in the natural creatures and objects. Over the past few decades, these biological switchable adhesives have inspired scientists to explore and engineer desirable artificial adhesives. In this review, we summarized the state-of-the-art research on the ultra-fast adhesive motion of three types of biological organisms (gecko, tree frog, and octopus). Firstly, the basic adhesion principles in the three representative organisms, including micro/nanostructures, interfacial forces, and fundamental adhesion models, are reviewed. Then, we discussed the adhesion mechanisms of the prominent organisms from the perspective of soft contacts between micro/nanostructures and the substrates. Later, the mechanics-guided design principles of artificial adhesive surfaces, as well as the smart adhesion strategies, are summarized. The applications of these bio-inspired switchable adhesives are demonstrated, including wearable electronic devices, soft grippers, and climbing robots. The challenges and opportunities in this fast-growing field are also discussed.

A Physical Model Approach to Gecko Adhesion Opportunity and Constraint: How Rough Could It Be?

It has been nearly 20 years since Autumn and colleagues established the central role of van der Waals intermolecular forces in how geckos stick. Much has been discovered about the structure and function of fibrillar adhesives in geckos and other taxa, and substantial success has been achieved in translating natural models into bioinspired synthetic adhesives. Nevertheless, synthetics still cannot match the multidimensional performance observed in the natural gecko system that is simultaneously robust to dirt and water, resilient over thousands of cycles, and purportedly competent on surfaces that are rough at drastically different length scales. Apparent insensitivity of adhesion to variability in roughness is particularly interesting from both a theoretical and applied perspective. Progress on understanding the extent to which and the basis of how the gecko adhesive system is robust to variation in roughness is impeded by the complexity of quantifying roughness of natural surfaces and a dearth of data on free-ranging gecko substrate use. Here we review the main challenges in characterizing rough surfaces as they relate to collecting relevant estimates of variation in gecko adhesive performance across different substrates in their natural habitats. In response to these challenges, we propose a practical protocol (borrowing from thermal biophysical ecological methods) that will enable researchers to design detailed studies of structure-function relationships of the gecko fibrillar system. Employing such an approach will help provide specific hypotheses about how adhesive pad structure translates into a capacity for robust gecko adhesion across large variation in substrate roughness. Preliminary data we present on this approach suggest its promise in advancing the study of how geckos deal with roughness variation. We argue and outline how such data can help advance development of design parameters to improve bioinspired adhesives based on the gecko fibrillar system.

The Ecomechanics of Gecko Adhesion: Natural Surface Topography, Evolution, and Biomimetics

The study of gecko adhesion is necessarily interdisciplinary due to the hierarchical nature of the adhesive system and the complexity of interactions between the animals and their habitats. In nature, geckos move on a wide range of surfaces including soft sand dunes, trees, and rocks, but much of the research over the past two decades has focused on their adhesive performance on artificial surfaces. Exploring the complex interactions between geckos and their natural habitats will reveal aspects of the adhesive system that can be applied to biomimetic research, such as the factors that facilitate movement on dirty and rough surfaces with varying microtopography. Additionally, contrasting suites of constraints and topographies are found on rocks and plants, likely driving differences in locomotion and morphology. Our overarching goals are to bring to light several aspects of ecology that are important for gecko–habitat interactions, and to propose a framework for how they can inspire material scientists and functional ecologists. We also present new data on surface roughness and topography of a variety of surfaces, and adhesive performance of Phelsuma geckos on surfaces of varying roughness. We address the following key questions: (1) why and how should ecology be incorporated into the study of gecko adhesion? (2) What topographical features of rocks and plants likely drive adhesive performance? (3) How can ecological studies inform material science research? Recent advances in surface replication techniques that eliminate confounding factors among surface types facilitate the ability to address some of these questions. We pinpoint gaps in our understanding and identify key initiatives that should be adopted as we move forward. Most importantly, fine details of locomotor microhabitat use of both diurnal and nocturnal geckos are needed.

Slanted Functional Gradient Micropillars for Optimal Bioinspired Dry Adhesion

For biologically inspired dry adhesives, the fibrillar structure of the surface requires sufficient flexibility to form contacts and meanwhile high rigidity to maintain stability. This fundamental conflict has greatly hindered the advance of synthetic adhesives toward mass-scale and practical applications, where adhesion is desired to be simultaneously strong, durable, directional, and roughness-adaptive. In this work, we overcome such a long-term challenge by developing fibrillar structures that combine both slanted geometry and gradient material of micropillars. The termed slanted functional gradient pillars (s-FGPs), fabricated by a magnetically assisted mold replication technique, exhibit flexible tips for contacts, gradually stiffened stalks for reinforcement, slanted structure to give rise to anisotropy, and high aspect ratio (AR) to facilitate surface adaptation. We demonstrate that the material and structure of the s-FGPs complement each other, synergetic effects of which result in a multifunctional combination of adhesion properties including high strength (∼9 N/cm² in shear), ultradurability (over 200 cycles of attachment/detachment without adhesion degradation), super anisotropy (anisotropic ratio of ∼7), and good adaptability to rough surfaces. The s-FGPs not only step forward the bioinspired adhesion toward optimized designs and performances for practical applications but may also open up other concepts for various high-AR and structurally stable fibrillar surfaces with emerging functionalities and applications in the fields of self-cleaning, superhydrophobicity, biosensors, energy harvesting, etc.

Influence of Humidity on Grip and Release Adhesion Mechanisms for Gecko-Inspired Microfibrillar Surfaces

Geckos have developed foot pads that allow them to maintain their unique climbing ability despite vast differences of surfaces and environments, from dry desert to humid rainforest. Likewise, successful gecko-inspired mimics should exhibit adhesive and frictional performance across a similarly diverse range of climates. In this work, we focus on the effect of relative humidity (RH) on the "frictional-adhesion" behavior of gecko-inspired adhesive pads. A surface forces apparatus was used to quantitatively measure adhesion and friction forces of a microfibrillar cross-linked polydimethylsiloxane surface against a smooth hemispherical glass disk at varying relative humidity, from 0 to 100% (including fully submerged under water). Geometrically anisotropic tilted half-cylinder microfibers yield a "grip state" (high adhesion and friction forces after shearing along the tilt of the fibers, F_ad⁺ and F_∥⁺) and a "release state" (low adhesion and friction after shearing against the tilt of the fibers, F_ad^- and F_∥^-). By appropriate control of the loading path, this allows for transition between strong attachment and easy detachment. Changing the preload and shear direction gives rise to differences in the effective contact area at each fiber and the microscale and nanoscale structure of the contact while changing the relative humidity results in differences in the relative contributions of van der Waals and capillary forces. In combination, both effects lead to interesting trends in the adhesion and friction forces. At up to 75% RH, the grip state adhesion force remains constant and the ratio of grip to release adhesion force does not drop below 4.0. In addition, the friction forces F_∥⁺ and F_∥^- and the release state adhesion force F_ad^- exhibit a maximum at intermediate relative humidity between 40% and 75%.

A Review of the State of Dry Adhesives: Biomimetic Structures and the Alternative Designs They Inspire

Robust and inexpensive dry adhesives would have a multitude of potential applications, but replicating the impressive adhesive organs of many small animals has proved challenging. A substantial body of work has been produced in recent years which has illuminated the many mechanical processes influencing a dry adhesive interface. The especially potent footpads of the tokay gecko have inspired researchers to develop and examine an impressive and diverse collection of artificial fibrillar dry adhesives, though study of tree frogs and insects demonstrate that successful adhesive designs come in many forms. This review discusses the current theoretical understanding of dry adhesive mechanics, including the observations from biological systems and the lessons learned by recent attempts to mimic them. Attention is drawn in particular to the growing contingent of work exploring ideas which are complimentary to or an alternative for fibrillar designs. The fundamentals of compliance control form a basis for dry adhesives made of composite and “smart,” stimuli-responsive materials including shape memory polymers. An overview of fabrication and test techniques, with a sampling of performance results, is provided.

Process, Design and Materials for Unidirectionally Tilted Polymeric Micro/Nanohairs and Their Adhesion Characteristics

Recent research in the field of gecko-inspired dry adhesive has focused on modifying the material and structural properties of polymer-based nanohairs. Polymers such as polystyrene (PS), high-density polyethylene (HDPE), ultraviolet curable epoxy (SU-8), polyurethane acrylate (PUA), polycarbonate (PC), and polydimethyl siloxane (PDMS) can fulfill many mechanical property requirements, are easily tunable, and can be produced via large-scale fabrication. However, the fabrication process for tilted structure remains challenging. The tilted structure is a crucial factor in high-degree conformal contact, which facilitates high adhesion, low effective modulus, and directional adhesion properties. Recent studies have attempted to create a tilted structure by applying beam irradiation, mechanical and thermal stress, and magnetic fields. This review provides a comprehensive investigation into advanced strategies for producing tilted polymeric nanostructures and their potential applications in the near future.

Understanding Surface Adhesion in Nature: A Peeling Model

Nature often exhibits various interesting and unique adhesive surfaces. The attempt to understand the natural adhesion phenomena can continuously guide the design of artificial adhesive surfaces by proposing simplified models of surface adhesion. Among those models, a peeling model can often effectively reflect the adhesive property between two surfaces during their attachment and detachment processes. In the context, this review summarizes the recent advances about the peeling model in understanding unique adhesive properties on natural and artificial surfaces. It mainly includes four parts: a brief introduction to natural surface adhesion, the theoretical basis and progress of the peeling model, application of the peeling model, and finally, conclusions. It is believed that this review is helpful to various fields, such as surface engineering, biomedicine, microelectronics, and so on.

A state-of-the-art review and analysis on the design of dry adhesion materials for applications such as climbing micro-robots

This article highlights the design considerations for the development of robust and durable bio-inspired synthetic adhesives.

The effect of drop volume and micropillar shape on the apparent contact angle of ordered microstructured surfaces

In the present paper, we propose a new theoretical approach to evaluate the shape and apparent contact angle (ACA) of a drop gently deposited on microstructured superhydrophobic surfaces. We exploit the very large separation of scales between the drop size and the features of the micromorphology of the interface to propose a numerical methodology to calculate the apparent contact area and apparent contact angle. In agreement with very recent experiments, calculations show that, in the case of surfaces made of conical micropillars, the ACA may take values very close to 180° not depending on the size of the liquid drop. At large drop volumes, the shape of the drop deviates from the spherical one as a result of the gravity effects, but it is noteworthy that the apparent contact angle does not change at all. Our calculations shows that this holds true also for different pillar shapes, showing that, for any given Young contact angle of the solid constituting the pillars, the ACA is an intrinsic property of the surface microgeometry.

Simulation of synthetic gecko arrays shearing on rough surfaces

To better understand the role of surface roughness and tip geometry in the adhesion of gecko synthetic adhesives, a model is developed that attempts to uncover the relationship between surface feature size and the adhesive terminal feature shape. This model is the first to predict the adhesive behaviour of a plurality of hairs acting in shear on simulated rough surfaces using analytically derived contact models. The models showed that the nanoscale geometry of the tip shape alters the macroscale adhesion of the array of fibres by nearly an order of magnitude, and that on sinusoidal surfaces with amplitudes much larger than the nanoscale features, spatula-shaped features can increase adhesive forces by 2.5 times on smooth surfaces and 10 times on rough surfaces. Interestingly, the summation of the fibres acting in concert shows behaviour much more complex that what could be predicted with the pull-off model of a single fibre. Both the Johnson-Kendall-Roberts and Kendall peel models can explain the experimentally observed frictional adhesion effect previously described in the literature. Similar to experimental results recently reported on the macroscale features of the gecko adhesive system, adhesion drops dramatically when surface roughness exceeds the size and spacing of the adhesive fibrillar features.

Controllable interfacial adhesion applied to transfer light and fragile objects by using gecko inspired mushroom-shaped pillar surface

Gecko-inspired surfaces are smart dry adhesive surfaces that have attracted much attention because of their wide range of potential applications. However, strong frictional force, rather than adhesive force, is frequently targeted in most of research in this area. In this study, the interfacial adhesive and frictional properties of a gecko-inspired mushroom-shaped polyurethane pillar array surface have been systematically characterized to design and control the interfacial adhesion of the surface by considering the nanoscale interfacial adhesion, the microscale structural compliance and deformation, and the macro-scale actuation. Matching the movement of the leg springs and the interfacial adhesive characteristics between the pillar array surfaces and substrates, a three-legged clamp prototype has been designed and fabricated to successfully pick up and release light and fragile objects with a smooth upper surface, such as a silicon wafer. These results provide a new insight into not only the theoretical understanding of the integrating adhesion mechanisms, but also the practical applications of utilizing and controlling the adhesive and frictional forces of gecko-inspired surfaces.

Scaling normal adhesion force capacity with a generalized parameter

The adhesive response of a rigid flat cylindrical indenter in contact with a compliant elastic layer of varying confinement is investigated experimentally and described analytically. Using a soft elastic gel with substrate thickness, t, and indenter radius, a, 28 unique combinations of the confinement parameter, a/t, are examined over a range of 0.016 < a/t < 7.2. Continuous force capacity predictions as a function of a/t and material properties are provided through a scaling theory and are found to agree well with the experimental data. We further collapse all of the data over orders of magnitude in adhesive force capacity onto a single line described by a generalized reversible adhesion scaling parameter, A/C, where A is the contact area and C is the compliance. As the scaling analysis does not assume a specific separation mechanism the adhesive force capacity is well described during both axisymmetric edge separation and during interfacial fingering and cavitation instabilities. We discuss how the geometry of the contact, specifically increasing the degree of confinement, allows reversible adhesive materials to be designed that are not "sticky" or "tacky", yet can be very strong and provide high performance.

Design of gecko-inspired fibrillar surfaces with strong attachment and easy-removal properties: a numerical analysis of peel-zone

Despite successful fabrication of gecko-inspired fibrillar surfaces with strong adhesion forces, how to achieve an easy-removal property becomes a major concern that may restrict the wide applications of these bio-inspired surfaces. Research on how geckos detach rapidly has inspired the design of novel adhesive surfaces with strong and reversible adhesion capabilities, which relies on further fundamental understanding of the peeling mechanisms. Recent studies showed that the peel-zone plays an important role in the peeling off of adhesive tapes or fibrillar surfaces. In this study, a numerical method was developed to evaluate peel-zone deformation and the resulting mechanical behaviour due to the deformations of fibrillar surfaces detaching from a smooth rigid substrate. The effect of the geometrical parameters of pillars and the stiffness of backing layer on the peel-zone and peel strength, and the strong attachment and easy-removal properties have been analysed to establish a design map for bio-inspired fibrillar surfaces, which shows that the optimized strong attachment and easy-removal properties can vary by over three orders of magnitude. The adhesion and peeling design map established provides new insights into the design and development of novel gecko-inspired fibrillar surfaces.

Sticky bio-inspired micropillars: finding the best shape

Very recently, both experimental and theoretical investigations have shown that microstructured surfaces covered with mushroom-shaped micropillars present strongly enhanced adhesive properties if compared to flat surfaces made of the same material. However, different geometries lead to different adhesive performance, and finding the optimal solution has become of utmost importance. This paper presents on which physical basis the optimal mushroom pillar shape should be sought, and it provides a relatively simple methodology to achieve the result. Calculations demonstrate that the adhesive performance of the pillar strongly depends on the geometry of the terminal plate. The best performance is achieved when the ratio s/R(i) between the plate thickness (s) and the pillar internal radius (R(i)) is close to 0.2-0.3, and the ratio R(e)/R(i) is larger than 2, where R(e) is the external radius of the plate.

Conformal adhesion enhancement on biomimetic microstructured surfaces

Inspired by the superior adhesive ability of the gecko foot pad, we report an experimental study of conformal adhesion of a soft elastomer thin film on biomimetic micropatterned surfaces (micropillars), showing a remarkable adhesion enhancement due to the surface patterning. The adhesion of a low-surface-energy poly(dimethylsiloxane) tape to a SU-8 micropatterned surface was found be able to increase by 550-fold as the aspect ratio increases from 0 to 6. The dependency of the adhesion enhancement on the aspect ratio is highly nonlinear. A series of peeling experiment coupled with optical interference imaging were performed to investigate the adhesion enhancement as a function of the height of the micropillars and the associated delamination mechanisms. Local elastic energy dissipation, side-wall friction, and plastic deformations were analyzed and discussed in terms of their contributions to the adhesion enhancement. We conclude that the local adhesion and friction events of pulling micropillars out of the embedded polymer film play a primary role in the observed adhesion enhancement. The technical implications of this local friction-based adhesion enhancement mechanism were discussed for the effective assembly of similar or dissimilar material components at small scales. The combined use of the micro/nanostructured surfaces with the van der Waals interactions seem to be a potentially more universal solution than the conventional adhesive bonding technology, which depends on the chemical and viscoelastic properties of the materials.

Effect of viscoelasticity on adhesion of bioinspired micropatterned epoxy surfaces

The effect of viscoelasticity on adhesion was investigated for micropatterned epoxy surfaces and compared to nonpatterned surfaces. A two-component epoxy system was used to produce epoxy compositions with different viscoelastic properties. Pillar arrays with flat punch tip geometries were fabricated with a two-step soft lithography process. Adhesion properties were measured with a home-built adhesion tester using a spherical sapphire probe as a counter-surface. Compared to flat controls, micropatterned epoxy samples with low viscoelasticity (i.e., low damping factors) showed at least a 20-fold reduction in pull-off force per actual contact area for both low (E' = 2.3 MPa) and high (E' = 2.3 GPa) storage moduli. This antiadhesive behavior may result from poor contact formation and indicates that the adhesion performance of commonly used elastomers for dry adhesives (e.g., polydimethylsiloxane) is governed by the interfacial viscoelasticity. Adhesion significantly increased with increasing viscoelasticity. Micropatterned samples with high viscoelasticity showed a 4-fold reduction in adhesion for aspect ratio (AR) 1.1 patterns but a 2-fold enhancement in adhesion for AR 2.2 patterns. These results indicate that viscoelasticity can enhance the effect of surface patterning on adhesion and should be considered as a significant parameter in the design of artificial patterned adhesives.

The effect of aspect ratio on adhesion and stiffness for soft elastic fibres

The effect of aspect ratio on the pull-off stress and stiffness of soft elastic fibres is studied using elasticity and numerical analysis. The adhesive interface between a soft fibre and a smooth rigid surface is modelled using the Dugdale-Barenblatt model. Numerical simulations show that, while pull-off stress increases with decreasing aspect ratio, fibres get stiffer. Also, for sufficiently low aspect ratio fibres, failure occurs via the growth of internal cracks and pull-off stress approaches the intrinsic adhesive strength. Experiments carried out with various aspect ratio polyurethane elastomer fibres are consistent with the numerical simulations.

Friction and adhesion of hierarchical carbon nanotube structures for biomimetic dry adhesives: multiscale modeling

With unique hierarchical fibrillar structures on their feet, gecko lizards can walk on vertical walls or even ceilings. Recent experiments have shown that strong binding along the shear direction and easy lifting in the normal direction can be achieved by forming unidirectional carbon nanotube array with laterally distributed tips similar to gecko's feet. In this study, a multiscale modeling approach was developed to analyze friction and adhesion behaviors of this hierarchical fibrillar system. Vertically aligned carbon nanotube array with laterally distributed segments at the end was simulated by coarse grained molecular dynamics. The effects of the laterally distributed segments on friction and adhesion strengths were analyzed, and further adopted as cohesive laws used in finite element analysis at device scale. The results show that the laterally distributed segments play an essential role in achieving high force anisotropy between normal and shear directions in the adhesives. Finite element analysis reveals a new friction-enhanced adhesion mechanism of the carbon nanotube array, which also exists in gecko adhesive system. The multiscale modeling provides an approach to bridge the microlevel structures of the carbon nanotube array with its macrolevel adhesive behaviors, and the predictions from this modeling give an insight into the mechanisms of gecko-mimicking dry adhesives.

Gecko-inspired surfaces: a path to strong and reversible dry adhesives

The amazing adhesion of gecko pads to almost any kind of surfaces has inspired a very active research direction over the last decade: the investigation of how geckos achieve this feat and how this knowledge can be turned into new strategies to reversibly join surfaces. This article reviews the fabrication approaches used so far for the creation of micro- and nanostructured fibrillar surfaces with adhesive properties. In the light of the pertinent contact mechanics, the adhesive properties are presented and discussed. The decisive design parameters are fiber radius and aspect ratio, tilt angle, hierarchical arrangement and the effect of the backing layer. Also first responsive systems that allow thermal switching between nonadhesive and adhesive states are described. These structures show a high potential of application, providing the remaining issues of robustness, reliability, and large-area manufacture can be solved.