Transparent, abrasion-insensitive superhydrophobic coatings for real-world applications

Approaching Standardization: Mechanical Material Testing of Macroscopic Two-Photon Polymerized Specimens

Two-photon polymerization (2PP) is becoming increasingly established as additive manufacturing technology for microfabrication due to its high-resolution and the feasibility of generating complex parts. Until now, the high resolution of 2PP is also its bottleneck, as it limited throughput and therefore restricted the application to the production of microparts. Thus, mechanical properties of 2PP materials can only be characterized using nonstandardized specialized microtesting methods. Due to recent advances in 2PP technology, it is now possible to produce parts in the size of several millimeters to even centimeters, finally permitting the fabrication of macrosized testing specimens. Besides suitable hardware systems, 2PP materials exhibiting favorable mechanical properties that allow printing of up-scaled parts are strongly demanded. In this work, the up-scalability of three different photopolymers is investigated using a high-throughput 2PP system and low numerical aperture optics. Testing specimens in the cm-range are produced and tested with common or even standardized material testing methods available in conventionally equipped polymer testing labs. Examples of the characterization of mechanical, thermo-mechanical, and fracture properties of 2PP processed materials are shown. Additionally, aspects such as postprocessing and aging are investigated. This lays a foundation for future expansion of the 2PP technology to broader industrial application.

Observing Real-Time Adhesion of Microparticles on Glass Surfaces

Fouling on glass surfaces reduces the solar panel efficiency and increases water consumption for cleaning. Superhydrophobic coatings on glass enable self-cleaning by allowing water droplets to carry away dirt particles. Observing the interaction between charged particles and surfaces provides insights into effective cleaning. Using a high-speed camera and a long-distance objective, we analyzed the in situ deposition of variously functionalized and charged silica dust microparticles on chemically treated glass. The ambient charges for the control, hydrophobic, and positively charged particles were approximately -0.5, -0.13, and +0.5 nC, respectively. We found that a positively charged particle of 2.3 ± 1.2 μm diameter adhered to hydroxylated glass in ∼0.054 s, compared to 0.40 and 0.45 s for quaternary ammonium- and fluorosilane-functionalized hydrophobic glass. Experiments suggest that quaternary ammonium-functionalized glass surfaces are about 77.8% more resistant to soiling than bare surfaces.

Superrepellent Porous Polymer Surfaces by Replication from Wrinkled Polydimethylsiloxane/Parylene F

Superrepellent surfaces, such as micro/nanostructured surfaces, are of key importance in both academia and industry for emerging applications in areas such as self-cleaning, drag reduction, and oil repellence. Engineering these surfaces is achieved through the combination of the required surface topography, such as porosity, with low-surface-energy materials. The surface topography is crucial for achieving high liquid repellence and low roll-off angles. In general, the combination of micro- and nanostructures is most promising in achieving high repellence. In this work, we report the enhancement of wetting properties of porous polymers by replication from wrinkled Parylene F (PF)-coated polydimethylsiloxane (PDMS). Fluorinated polymer foam “Fluoropor” serves as the low-surface-energy polymer. The wrinkled molds are achieved via the deposition of a thin PF layer onto the soft PDMS substrates. Through consecutive supercritical drying, superrepellent surfaces with a high surface porosity and a high water contact angle (CA) of >165° are achieved. The replicated surfaces show low roll-off angles (ROA) <10° for water and <21° for ethylene glycol. Moreover, the introduction of the micro-wrinkles to Fluoropor not only enhances its liquid repellence for water and ethylene glycol but also for liquids with low surface tension, such as n-hexadecane.

Application of Micro/Nanoporous Fluoropolymers with Reduced Bioadhesion in Digital Microfluidics

Digital microfluidics (DMF) is a versatile platform for conducting a variety of biological and chemical assays. The most commonly used set-up for the actuation of microliter droplets is electrowetting on dielectric (EWOD), where the liquid is moved by an electrostatic force on a dielectric layer. Superhydrophobic materials are promising materials for dielectric layers, especially since the minimum contact between droplet and surface is key for low adhesion of biomolecules, as it causes droplet pinning and cross contamination. However, superhydrophobic surfaces show limitations, such as full wetting transition between Cassie and Wenzel under applied voltage, expensive and complex fabrication and difficult integration into already existing devices. Here we present Fluoropor, a superhydrophobic fluorinated polymer foam with pores on the micro/nanoscale as a dielectric layer in DMF. Fluoropor shows stable wetting properties with no significant changes in the wetting behavior, or full wetting transition, until potentials of 400 V. Furthermore, Fluoropor shows low attachment of biomolecules to the surface upon droplet movement. Due to its simple fabrication process, its resistance to adhesion of biomolecules and the fact it is capable of being integrated and exchanged as thin films into commercial DMF devices, Fluoropor is a promising material for wide application in DMF.

Microstructured Surfaces for Reducing Chances of Fomite Transmission via Virus-Containing Respiratory Droplets

Evaporation-induced particle aggregation in drying droplets is of significant importance in the prevention of pathogen transfer due to the possibility of indirect fomite transmission of the infectious virus particles. In this study, particle aggregation was directionally controlled using contact line dynamics (pinned or slipping) and geometrical gradients on microstructured surfaces by the systematic investigation of the evaporation process on sessile droplets and sprayed microdroplets laden with virus-simulant nanoparticles. Using this mechanism, we designed robust particle capture surfaces by significantly inhibiting the contact transfer of particles from fomite surfaces. For the proof-of-concept, interconnected hexagonal and inverted pyramidal microwall were fabricated using ultraviolet-based nanoimprint lithography, which is considered to be a promising scalable manufacturing process. We demonstrated the potentials of an engineered microcavity surface to limit the contact transfer of particle aggregates deposited with the evaporation of microdroplets by 93% for hexagonal microwall and by 96% for inverted pyramidal microwall. The particle capture potential of the interconnected microstructures was also investigated using biological particles, including adenoviruses and lung-derived extracellular vesicles. The findings indicate that the proposed microstructured surfaces can reduce the indirect fomite transmission of highly infectious agents, including norovirus, rotavirus, or SARS-CoV-2, via respiratory droplets.

Memory effects in polymer brushes showing co-nonsolvency effects

Densely packed polymer chains grafted to a substrate, especially polymer brushes, have been studied intensively. Of special interest are systems that react to changes in external conditions or"remember" previous conditions. With this focus, we explore the properties of PNiPAAm brushes and relate published work to own results. The co-nonsolvency effect leads to a collapse of a PNiPAAm brush for a certain mixing ratio of ethanol in water. This also influences the wetting behavior of PNiPAAm brushes. We show that through prewetting of a brush with different liquids (water and ethanol), the contact angle of subsequent water drops changes significantly. To explain this change, the swelling of the brush was investigated with spectroscopic ellipsometry and the orientation of the molecules at the surface with sum-frequency generation (SFG). Only little change in swelling was found. The SFG measurements reveal in the ethanol prewetted case a well ordered hydrophobic methyl layer at the interface, which is consistent with the contact angle measurement.

Selective Fluorination of the Surface of Polymeric Materials after Stereolithography 3D Printing

With the microfluidics community embracing 3D resin printing as a rapid fabrication method, controlling surface chemistry has emerged as a new challenge. Fluorination of 3D-printed surfaces is highly desirable in many applications due to chemical inertness, low friction coefficients, antifouling properties, and the potential for selective hydrophobic patterning. Despite sporadic reports, silanization methods have not been optimized for covalent bonding with polymeric resins. As a case study, we tested the silanization of a commercially available (meth)acrylate-based resin (BV-007A) with a fluoroalkyl trichlorosilane. Interestingly, plasma oxidation was unnecessary for silanization of this resin and indeed was ineffective. Solvent-based deposition in a fluorinated oil (FC-40) generated significantly higher contact angles than deposition in ethanol or gas-phase deposition, yielding hydrophobic surfaces with contact angle >110° under optimized conditions. Attenuated total reflectance-Fourier transform infrared spectroscopy indicated that the increase in the contact angle correlated with consumption of a carbonyl moiety, suggesting covalent bonding of silane without plasma oxidation. Consistent with a covalent bond, silanization was resistant to mechanical damage and hydrolysis in methanol and was stable over long-term storage. When tested on a suite of photocrosslinkable resins, this silanization protocol generated highly hydrophobic surfaces (contact angle > 110°) on three resins and moderate hydrophobicity (90-100°) on the remainder. Selective patterning of hydrophobic regions in an open 3D-printed microchannel was possible in combination with simple masking techniques. Thus, this facile fluorination strategy is expected to be applicable for resin-printed materials in a variety of contexts including micropatterning and multiphase microfluidics.

Potential of Superhydrophobic Surface for Blood-Contacting Medical Devices

Medical devices are indispensable in the healthcare setting, ranging from diagnostic tools to therapeutic instruments, and even supporting equipment. However, these medical devices may be associated with life-threatening complications when exposed to blood. To date, medical device-related infections have been a major drawback causing high mortality. Device-induced hemolysis, albeit often neglected, results in negative impacts, including thrombotic events. Various strategies have been approached to overcome these issues, but the outcomes are yet to be considered as successful. Recently, superhydrophobic materials or coatings have been brought to attention in various fields. Superhydrophobic surfaces are proposed to be ideal blood-compatible biomaterials attributed to their beneficial characteristics. Reports have substantiated the blood repellence of a superhydrophobic surface, which helps to prevent damage on blood cells upon cell-surface interaction, thereby alleviating subsequent complications. The anti-biofouling effect of superhydrophobic surfaces is also desired in medical devices as it resists the adhesion of organic substances, such as blood cells and microorganisms. In this review, we will focus on the discussion about the potential contribution of superhydrophobic surfaces on enhancing the hemocompatibility of blood-contacting medical devices.

3D-Printable Fluoropolymer Gas Diffusion Layers for CO2 Electroreduction

The electrosynthesis of value-added multicarbon products from CO₂ is a promising strategy to shift chemical production away from fossil fuels. Particularly important is the rational design of gas diffusion electrode (GDE) assemblies to react selectively, at scale, and at high rates. However, the understanding of the gas diffusion layer (GDL) in these assemblies is limited for the CO₂ reduction reaction (CO₂ RR): particularly important, but incompletely understood, is how the GDL modulates product distributions of catalysts operating in high current density regimes > 300 mA cm^-2 . Here, 3D-printable fluoropolymer GDLs with tunable microporosity and structure are reported and probe the effects of permeance, microstructural porosity, macrostructure, and surface morphology. Under a given choice of applied electrochemical potential and electrolyte, a 100× increase in the C₂ H₄ :CO ratio due to GDL surface morphology design over a homogeneously porous equivalent and a 1.8× increase in the C₂ H₄ partial current density due to a pyramidal macrostructure are observed. These findings offer routes to improve CO₂ RR GDEs as a platform for 3D catalyst design.

Fluoropolymers in biomedical applications: state-of-the-art and future perspectives

Biomedical applications of fluoropolymers in gene delivery, protein delivery, drug delivery, ¹⁹F MRI, PDT, anti-fouling, anti-bacterial, cell culture, and tissue engineering.

Imparting Superhydrophobicity with a Hierarchical Block Copolymer Coating

A robust and transparent silica-like coating that imparts superhydrophobicity to a surface through its hierarchical multilevel self-assembled structure is demonstrated. This approach involves iterative steps of spin-coating, annealing, and etching of polystyrene-block-polydimethylsiloxane block copolymer thin films to form a tailored multilayer nanoscale topographic pattern with a water contact angle up to 155°. A model based on the hierarchical topography is developed to calculate the wetting angle and optimize the superhydrophobicity, in agreement with the experimental trends, and explaining superhydrophobicity arising through the combination of roughness at different lengthscales. Additionally, the mechanical robustness and optically passive properties of the resulting hydrophobic surfaces are demonstrated.

High-Performance Materials for 3D Printing in Chemical Synthesis Applications

3D printing has emerged as an enabling technology for miniaturization. High-precision printing techniques such as stereolithography are capable of printing microreactors and lab-on-a-chip devices for efficient parallelization of biological and biochemical reactions under reduced uptake of reactants. In the world of chemistry, however, up until now, miniaturization has played a minor role. The chemical and thermal stability of regular 3D printing resins is insufficient for sustaining the harsh conditions of chemical reactions. Novel material formulations that produce highly stable 3D-printed chips are highly sought for bringing chemistry up-to-date on the development of miniaturization. In this work, a brief review of recent developments in highly stable materials for 3D printing is given. This work focuses on three highly stable 3D-printable material systems: transparent silicate glasses, ceramics, and fluorinated polymers. It is further demonstrated that 3D printing is also a versatile technique for surface structuring of polymers to enhance their wetting performance. Such micro/nanostructuring is key to selectively wetting surface patterns that are versatile for chemical arrays and droplet synthesis.

Is dropwise condensation feasible? A review on surface modifications for continuous dropwise condensation and a profitability analysis

The interest in surface treatments promoting dropwise condensation has grown exponentially in the past decades. Savings in the operating and maintenance costs of steam processes involving phase changes are promised. Numerous surface preparation methods allow the formation of droplets during condensation. However, stable dropwise condensation has been hardly realized in industrial applications. This review aims to highlight the surface preparation techniques that promote dropwise condensation. It emphasizes on their durability and the resulting stability of dropwise condensation. Furthermore, the possibilities of implementation at an industrial level are discussed, apart from evaluating the economic feasibility through a case study. Despite years of research and numerous surface design possibilities, dropwise condensation cannot be maintained: coating deterioration and fluctuating process conditions commonly lead to surface flooding within hours or weeks. A more profound understanding of the mechanisms of dropwise condensation and innovative design concepts for self-renewing heat transfer surfaces may diminish encountered challenges.

Study of Biofilm Growth on Slippery Liquid-Infused Porous Surfaces Made from Fluoropor

Undesired growth of biofilms represents a fundamental problem for all surfaces in long-term contact with aqueous media. Mature biofilms resist most biocide treatments and often are a pathogenic threat. One way to prevent biofilm growth on surfaces is by using slippery liquid-infused porous surfaces (SLIPS). SLIPS consist of a porous substrate which is infused with a lubricant immiscible with the aqueous medium in which the bacteria are suspended. Because of the lubricant, bacteria cannot attach to the substrate surface and thus formation of the biofilm is prevented. For this purpose, we manufactured substrates with different porosity and surface roughness values via UV-initiated free-radical polymerization in Fluoropor. Fluoropor is a class of highly fluorinated bulk-porous polymers with tunable porosity, which we recently introduced. We investigated the growth of the biofilm on the substrates, showing that a reduced surface roughness is beneficial for the reduction of biofilm growth. Samples of low roughness effectively reduced Pseudomonas aeruginosa biofilm growth for 7 days in a flow chamber experiment. The low-roughness samples also become transparent when infused with the lubricant, making such surfaces ideal for real-time observation of biofilm growth by optical examination.

Decomposable Polyvinyl Alcohol-Based Super-Hydrophobic Three-Dimensional Porous Material for Effective Water/Oil Separation

The development of the oil industry brings the critical problem of ocean pollution by oil spill or fossil fuels. The use of materials for water/oil separation is one of the effective approaches to solve this crisis. Polyvinyl alcohol (PVA) has been used  to prepare water/oil separation materials. Currently, glutaraldehyde has been employed as the cross-linking agent, which is well known to be toxic and environmentally unfriendly. Moreover, it is difficult to deal with the disposal of the Across-linked material. Here, we propose a strategy of fabricating macroporous material which was prepared by PVA and sodium silicate (Na₂SiO₃) in aqueous solution. Following through with the one-step method of sol-gel reaction of hydroxyl groups with trimethoxy(octadecyl)silane, the low surface energy substance was grafted on the macroporous material and a super-hydrophobic macroporous membrane for water/oil separation was prepared. As oil sorbent, the as-prepared dried super-hydrophobic PVA/Na₂SiO₃ porous materials (PSD6S) have the adsorption capacity of 1.8-7.0 g/g for oil uptake, which depends on the type of oil liquid. Typically, the separation efficiency of this material could reach more than 99% even after 10 times of use without the help of ambient pressure. It is noteworthy that the as-prepared samples could be easily decomposable and dissolvable completely in acidic medium at a rapid rate.

The anti-soiling performance of highly reflective superhydrophobic nanoparticle-textured mirrors

The anti-soiling (AS) performance of solar mirrors coated with a highly transparent, superhydrophobic nanoparticle-textured coating has been characterized. The AS coatings were created on the mirror surface by depositing nano-textured silica nanoparticle layers of ∼250 nm thickness using a draw-down coating process, followed by fluorination of the nanoparticles in a molecular vapor deposition process. Highly uniform surface features of the AS-coated mirrors (20 × 30 cm2, no measurable loss in specular reflectance, and water contact angle >165°) provided an outstanding AS performance. A 4× reduction in the rate of dust accumulation as determined by gravimetric measurement of the accumulated dust on coated versus uncoated mirrors was observed. Additional evidence of a significant reduction in soiling rate was determined during measurements of specular reflectance in an outdoor environment test. The adhesion force between a model sand particle and nano-textured coatings in the hydrophobic to superhydrophobic range was also studied. A dramatic decrease in adhesive force acting on the particle was observed with increasing surface hydrophobicity. The results align well with the observed dust accumulation on the AS-coated mirrors. The AS-coated mirror maintains a high reflectivity by shedding dust and resisting dust accumulation, providing a potential benefit when applied to mirrors in the solar field of a concentrated solar power generation plant.

Superwetting copper meshes based on self-organized robust CuO nanorods: efficient water purification for in situ oil removal and visible light photodegradation

Water pollution has become a prominent environmental problem and insoluble oils and soluble dyes are the primary pollution sources. Herein, a facile and environment friendly method is proposed to fabricate robust CuO nanorod-covered meshes for dual-functional water purification. The as-prepared meshes can efficiently eliminate oils in wastewater and in situ photodegrade soluble organic dyes under visible light irradiation. Such a functional mesh is free-standing and recyclable, indicating the outstanding practicability of water sewage disposal. In consideration of the superiority of low-cost materials, simple method, visible-light response, ultrahigh purification efficiency and reusability, the as-prepared meshes are promising in the field of multi-functional water purification.