Drawing-Based Manufacturing of Shear-Activated Reversible Adhesives

Aphid-Inspired and Thermally-Actuated Soft Gripper Using 3D Printing Technology

Herein, a thermo-actuated aphid-inspired dry adhesive (TADA) that offers tunable and reversible adhesion is reported. It is easily fabricated through 3D printing using a polylactic acid (PLA) filament and silicone elastomer, avoiding the use of unfavorable methods for micro- and nanofabrication and unwanted particles for actuation. The tunable adhesive system mimics aphid biology to achieve adhesion switchability. Switching between adhesion states is enabled by the thermo-actuated PLA, which has shape memory properties. Additionally, silicone elastomer enables adherence to flat substrates such as glass, silicon wafers, and acrylic plates. The detachment time of the TADA can be controlled by changing the printing layer height, which is a 3D-printing parameter that results in a short detachment time when the printing layer height is small. The adhesion strength is measured by applying different preloads and varying the size of the adhesive area. The reversibility between the adhesion-on and adhesion-off states, revealing good repeatability with similar adhesion strengths is also demonstrated. The TADA has potential applications in transferring silicon wafers. In addition, it can be printed to fit a flat plate of any shape, enabling it to grip the plate stably.

Enhanced Flexible Mold Lifetime for Roll-to-Roll Scaled-Up Manufacturing of Adhesive Complex Microstructures

Various functional complex 3D patterned surfaces with micro- or nanostructures have been developed and their superior performances over non-patterned smooth surfaces proven. However, it is challenging to mass-produce such complex micro-/nanopatterned surfaces, which limits their commercialization drastically. Although roll-to-roll (R2R) manufacturing using flexible molds has been implemented for mass-production of such functional surfaces, the poor mold repeatability issue has not been resolved yet. Here, a strategy to significantly improve the repeatability of the micropatterned flexible silicone molds over 1000 cycles against highly adhesive polyurethane acrylates (PUAs) in UV light curing based R2R systems by using a two-step curing process is reported. The mold repeatability is drastically increased from 10s of cycles to over 1000 cycles through the proposed strategy in spite of the complicated 3D undercut geometry and high tackiness of the microstructure. This two-step process would enable scaled-up production of micro-/nanostructured adhesives, such as gecko-inspired microfiber adhesives as demonstrated in this study, as well as various other functional micro-/nanostructured surfaces by enhancing the flexible mold lifetime.

Fast, strong, and reversible adhesives with dynamic covalent bonds for potential use in wound dressing

Adhesives typically fall into two categories: those that have high but irreversible adhesion strength due to the formation of covalent bonds at the interface and are slow to deploy, and others that are fast to deploy and the adhesion is reversible but weak in strength due to formation of noncovalent bonds. Synergizing the advantages from both categories remains challenging but pivotal for the development of the next generation of wound dressing adhesives. Here, we report a fast and reversible adhesive consisting of dynamic boronic ester covalent bonds, formed between poly(vinyl alcohol) (PVA) and boric acid (BA) for potential use as a wound dressing adhesive. Mechanical testing shows that the adhesive film has strength in shear of 61 N/cm² and transcutaneous adhesive strength of 511 N/cm², generated within 2 min of application. Yet the film can be effortlessly debonded when exposed to excess water. The mechanical properties of PVA/BA adhesives are tunable by varying the cross-linking density. Within seconds of activation by water, the surface boronic ester bonds in the PVA/BA film undergo fast debonding and instant softening, leading to conformal contact with the adherends and reformation of the boronic ester bonds at the interface. Meanwhile, the bulk film remains dehydrated to offer efficient load transmission, which is important to achieve strong adhesion without delamination at the interface. Whether the substrate surface is smooth (e.g., glass) or rough (e.g., hairy mouse skin), PVA/BA adhesives demonstrate superior adhesion compared to the most widely used topical skin adhesive in clinical medicine, Dermabond.

Amplification factor in shear-activated adhesives: effect of elasticity

In contrast to common adhesives used in joining, directional adhesives are designed for a dynamic attachment/detachment operation and, hence, their performance is assessed not only in an activated mode but also in a disactivated mode. Consequently, in addition to a peak adhesive strength, a ratio of maximum over minimum attachment force, which can be called a shear-driven amplification factor, is utilized for their characterization. Considering that the peak adhesive response and the amplification factor both depend on the elasticity of the microstructured surface, here we report a combined numerical and experimental study of the effect of the Young's modulus on the attachment properties of flap-shaped contact elements drawn from polyurethane. Our results demonstrate that while the activated and disactivated pull-off forces decrease, the amplification factor increases as the Young's modulus increases. Given that both the activated pull-off force and the amplification factor should be maximized for the best performance, the Young's modulus has to be carefully chosen based on the characteristics of the objects to be manipulated.