Crack engineering for the construction of arbitrary hierarchical architectures

Manufacturing of Bionic Adhesion Microstructure with Expanded Ends Based on Electroplating in the Restricted Area

The organisms of animals with full spatial motion ability present fine and complex 3D structures, showing reliable adhesion ability to the substrate. As core issues, the design and manufacture of complex morphology are essential in bionic adhesion technology. Specifically, the end-expanded microstructure array of high adhesion under low preload has widespread potential in the nondestructive fixation and handling of fragile objects. In the fabrication of end-expanded microstructures, the design and manufacture of metal molds with good mechanical strength are the key. In this paper, a microfabrication technology for manufacturing nickel molds based on three-dimensional printing and electroplating was proposed. The effect of the electric field inhomogeneity on the electrodeposition morphology was systematically studied. Typical bionic adhesives with expanded ends were obtained by a roll-to-roll hot embossing (R2R-HE) process. The normal adhesion force of the bionic adhesives is 9.5 N/cm2, which is comparable to that of the gecko. The electroplating process assisted by 3D printing provides a new approach for the fabrication of complex bionic morphologies and large-area bionic adhesion structures.

Nature-inspired adhesive systems

Many organisms in nature thrive in intricate habitats through their unique bio-adhesive surfaces, facilitating tasks such as capturing prey and reproduction. It's important to note that the remarkable adhesion properties found in these natural biological surfaces primarily arise from their distinct micro- and nanostructures and/or chemical compositions. To create artificial surfaces with superior adhesion capabilities, researchers delve deeper into the underlying mechanisms of these captivating adhesion phenomena to draw inspiration. This article provides a systematic overview of various biological surfaces with different adhesion mechanisms, focusing on surface micro- and nanostructures and/or chemistry, offering design principles for their artificial counterparts. Here, the basic interactions and adhesion models of natural biological surfaces are introduced first. This will be followed by an exploration of research advancements in natural and artificial adhesive surfaces including both dry adhesive surfaces and wet/underwater adhesive surfaces, along with relevant adhesion characterization techniques. Special attention is paid to stimulus-responsive smart artificial adhesive surfaces with tunable adhesive properties. The goal is to spotlight recent advancements, identify common themes, and explore fundamental distinctions to pinpoint the present challenges and prospects in this field.

A Reflectivity Enhanced 3D Optical Storage Nanostructure Application Based on Direct Laser Writing Lithography

To enable high-density optical storage, better storage media structures, diversified recording methods, and improved accuracy of readout schemes should be considered. In this study, we propose a novel three-dimensional (3D) sloppy nanostructure as the optical storage device, and this nanostructure can be fabricated using the 3D laser direct writing technology. It is a 900 nm high, 1 × 2 µm wide Si slope on a 200 nm SiO2 layer with 200 nm Si₃N₄ deposited on top to enhance reflectivity. In this study, we propose a reflected spectrum-based method as the readout recording strategy to stabilize information readout more stable. The corresponding reflected spectrum varied when the side wall angle of the slope and the azimuth angle of the nanostructure were tuned. In addition, an artificial neural network was applied to readout the stored information from the reflected spectrum. To simulate the realistic fabrication error and measurement error, a 20% noise level was added to the study. Our findings showed that the readout accuracy was 99.86% for all 120 data sequences when the slope and azimuth angle were varied. We investigated the possibility of a higher storage density to fully demonstrate the storage superiority of this designed structure. Our findings also showed that the readout accuracy can reach its highest level at 97.25% when the storage step of the encoded structure becomes 7.5 times smaller. The study provides the possibility to further explore different nanostructures to achieve high-density optical storage.

All-perfluoropolymer, nonlinear stability-assisted monolithic surface combines topology-specific superwettability with ultradurability

Developing versatile and robust surfaces that mimic the skins of living beings to regulate air/liquid/solid matter is critical for many bioinspired applications. Despite notable achievements, such as in the case of developing robust superhydrophobic surfaces, it remains elusive to realize simultaneously topology-specific superwettability and multipronged durability owing to their inherent tradeoff and the lack of a scalable fabrication method. Here, we present a largely unexplored strategy of preparing an all-perfluoropolymer (Teflon), nonlinear stability-assisted monolithic surface for efficient regulating matters. The key to achieving topology-specific superwettability and multilevel durability is the geometric-material mechanics design coupling superwettability stability and mechanical strength. The versatility of the surface is evidenced by its manufacturing feasibility, multiple-use modes (coating, membrane, and adhesive tape), long-term air trapping in 9-m-deep water, low-fouling droplet transportation, and self-cleaning of nanodirt. We also demonstrate its multilevel durability, including strong substrate adhesion, mechanical robustness, and chemical stability, all of which are needed for real-world applications.

Flexible Superhydrophobic Microlens Arrays for Humid Outdoor Environment Applications

A microlens array (MLA) is an essential optical imaging device in the applications of augmented and virtual realities. The imaging of MLA would become blurry in a humid outdoor atmosphere. While the incorporation of superhydrophobicity to MLA would prevent the adhesion of droplets, the complex structure and the multiple fabrication process reduce the capability of optical imaging of MLA. Herein, a flexible superhydrophobic MLA with good optical imaging capability is successfully fabricated by the combination of 3D direct laser writing (DLW) and soft lithography. 3D DLW allows the fabrication of MLA with a hierarchical pillar array (h-MLA) in one step, which ensures good optical properties of the resulting polydimethylsiloxane (PDMS) h-MLA. The resulting h-MLAs with pitches ranging between 50 and 100 μm are superhydrophobic from which water droplets slide away at a sliding angle smaller than 15.6° and bounce off from the surface. Meanwhile, the hierarchical pillar array has a limited impact on the imaging capability and the field of view of h-MLA. With an optimized pitch of 60 μm, h-MLA has a transparency as good as MLA. Moreover, PDMS h-MLA retains excellent optical and superhydrophobic properties when bent and in an extremely humid environment. We believe that the proposed h-MLA could find applications in outdoor environments.

Fresnel Diffraction Strategy Enables the Fabrication of Flexible Superomniphobic Surfaces

Doubly re-entrant surfaces inspired by springtails exhibit excellent repellency to low-surface-tension liquid. However, the flexible doubly re-entrant surfaces are difficult to fabricate, especially for the overhang of the structure. Herein, we demonstrate a simple Fresnel aperture diffraction modulation strategy in microscale lithography coupled with a molding process to obtain the flexible doubly re-entrant superomniphobic surfaces with nanoscale overhangs. The negative nanoscale overhang features were formed in a single-layer photoresist due to the fine-modulation of the optical intensity fluctuation of the Fresnel aperture diffraction. The as-prepared flexible non-fluorinated polydimethylsiloxane (PDMS) doubly re-entrant microstructure based on the Fresnel aperture diffraction (D-BF) surface (without any additional treatments) could repel ethanol droplets (21.8 mN m^-1) in the Cassie-Baxter state. The robust nanoscale overhangs obtained by the molding process enable the maximum breakthrough pressure for the low-surface-tension ethanol droplets on the D-BF surfaces up to about 230 Pa, allowing ethanol liquids with Weber numbers up to 8.7 to fully bounce off. The fabricated non-fluorinated D-BF superomniphobic surface maintains outstanding liquid repellency after the surface wettability modification and deformation test.

Micromolding of Thermoplastic Polymers for Direct Fabrication of Discrete, Multilayered Microparticles

Soft lithography provides a convenient and effective method for the fabrication of microdevices with uniform size and shape. However, formation of an embossed, connective film as opposed to discrete features has been an enduring shortcoming associated with soft lithography. Removing this residual layer requires additional postprocessing steps that are often incompatible with organic materials. This limits adaptation and widespread realization of soft lithography for broader applications particularly in drug discovery and drug delivery fields. A novel and versatile approach is demonstrated that enables fabrication of discrete, multilayered, fillable, and harvestable microparticles directly from any thermoplastic polymer, even at very high molecular weights. The approach, isolated microparticle replication via surface-segregating polymer blend mold, utilizes a random copolymer additive, designed with a highly fluorinated segment that, when blended with the mold's matrix, spontaneously orients to the surface conferring an extremely low surface energy and nonwetting properties to the template. The extremely nonwetting properties of the mold are further utilized to load soluble biologics directly into the built-in microwells in a rapid and efficient manner using an innovative screen-printing approach. It is believed that this approach holds promise for fabrication of large-array, 3D, complex microstructures, and is a significant step toward clinical translation of microfabrication technologies.

Recent progress on crack pattern formation in thin films

Fascinating pattern formation by quasi-static crack growth in thin films has received increasing interest in both interdisciplinary science and engineering applications. The paper mainly reviews recent experimental and theoretical progress on the morphogenesis and propagation of various quasi-static crack patterns in thin films. Several key factors due to changes in loading types and substrate confinement for choosing crack paths toward different patterns are summarized. Moreover, the effect of crack propagation coupled to other competing or coexisting stress-relaxation processes in thin films, such as interface debonding/delamination and buckling instability, on the formation and transition of crack patterns is discussed. Discussions on the sources and changes in the driving force that determine crack pattern evolution may provide guidelines for the reliability and failure mechanism of thin film structures by cracking and for controllable fabrication of various crack patterns in thin films.

Recent Progress on Bioinspired Antibacterial Surfaces for Biomedical Application

Surface bacterial fouling has become an urgent global challenge that calls for resilient solutions. Despite the effectiveness in combating bacterial invasion, antibiotics are susceptible to causing microbial antibiotic resistance that threatens human health and compromises the medication efficacy. In nature, many organisms have evolved a myriad of surfaces with specific physicochemical properties to combat bacteria in diverse environments, providing important inspirations for implementing bioinspired approaches. This review highlights representative natural antibacterial surfaces and discusses their corresponding mechanisms, including repelling adherent bacteria through tailoring surface wettability and mechanically killing bacteria via engineering surface textures. Following this, we present the recent progress in bioinspired active and passive antibacterial strategies. Finally, the biomedical applications and the prospects of these antibacterial surfaces are discussed.

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.

Robust and durable liquid-repellent surfaces

This review provides a comprehensive summary of characterization, design, fabrication, and application of robust and durable liquid-repellent surfaces.

Hydrophilic Slippery Surface Promotes Efficient Defrosting

Frost accretion occurs ubiquitously in various industrial applications and causes tremendous energy and economic loss, as manifested by the Texas power crisis that impacted millions of people over a vast area in 2021. To date, extensive efforts have been made on frost removal by micro-engineering surfaces with superhydrophobicity or lubricity. On such surfaces, air or oil cushions are introduced to suspend the frost layer and promote the rapid frost sliding off, which, although promising, faces the instability of the cushions under extreme frosting conditions. Most existing hydrophilic surfaces, characterized by large interfacial adhesion, have long been deemed unfavorable for frost shedding. Here, we demonstrated that a hydrophilic and slippery surface can achieve efficient defrosting. On such a surface, the hydrophilicity gave rise to a highly interconnected basal frost layer that boosted the substrate-to-frost heat transfer; then, the resulting melted frost readily slid off the surface due to the superb slipperiness. Notably, on our surface, the retained meltwater coverage after frost sliding off was only 2%. In comparison to two control surfaces, for example, surfaces lacking either hydrophilicity or slipperiness, the defrosting efficiency was 13 and 19 times higher and the energy consumption was 2.3 and 6.2 times lower, respectively. Our study highlights the use of a hydrophilic surface for the pronounced defrosting in a broad range of industrial applications.

One-level microstructure-arrayed hydrophobic surface with low surface adhesion and strong anti-wetting function

To achieve both a low surface adhesion function and a high anti-wetting function, it is generally necessary to introduce multi-level micro-nano-structures on a surface. However, this will bring the difficulty of preparation technology, and the functions will fail due to the fact that the nanostructures can easily be damaged. In this research, the surface adhesion and anti-wetting properties of several typically one-level microstructure-arrayed hydrophobic surfaces are analyzed with the dynamics theory, including a square pillar-arrayed three-dimensional microstructure, a conical table-arrayed microstructure, and square frustum-arrayed microstructure. It is found that the anti-adhesion performance and anti-wetting property cannot achieve the best performance simultaneously on the one-level microstructure arrayed surfaces. Either the critical pressure of anti-wetting is finite when the surface adhesion is the lowest, or both the anti-adhesion and anti-wetting capacities are finite. However, an interesting phenomenon is found in that the square frustum-arrayed surface can not only achieve an almost infinite anti-wetting capacity when the distance between neighboring microstructures vanishes, but also reach near-zero adhesion when the square frustum reduces to a square pyramid. All the theoretical predictions are further verified by precise numerical simulations. The results of this paper should be helpful for the design of surfaces with low surface adhesion and strong anti-wetting functions in practical engineering.

Shape-Deformed Mushroom-like Reentrant Structures for Robust Liquid-Repellent Surfaces

Artificial liquid-repellent surfaces inspired by biomimetic structures provide a wide range of functional surfaces for various practical applications, such as self-cleaning, antisticking, oil/water separation, and droplet manipulation. However, functional biomimetic structures cannot be fabricated using conventional techniques. For example, mushroom-like topologies on the skin of springtails, which are referred to as "doubly reentrant structures," have attracted significant attention owing to their extraordinary liquid-repellent properties. Current methods of fabricating these reentrant structures have several limitations, such as complex material systems, processing steps, and additional chemical treatments. This study proposed a simple micro-shape-deformed approach to fabricate mushroom-like reentrant structures by digital light processing, a three-dimensional (3D) printing technique, with volumetric shrinkage. The nonuniform cross-linking process and light propagation during photopolymerization caused the deformation of the topological patterns atop the micropillar arrays, resulting in bent structures for mushroom-like shape-deformed microarchitectures. This 3D-printed shape-deformed microstructure exhibits a highly stable liquid repellency without perfluorinated coatings.

Femtosecond laser programmed artificial musculoskeletal systems

Natural musculoskeletal systems have been widely recognized as an advanced robotic model for designing robust yet flexible microbots. However, the development of artificial musculoskeletal systems at micro-nanoscale currently remains a big challenge, since it requires precise assembly of two or more materials of distinct properties into complex 3D micro/nanostructures. In this study, we report femtosecond laser programmed artificial musculoskeletal systems for prototyping 3D microbots, using relatively stiff SU-8 as the skeleton and pH-responsive protein (bovine serum albumin, BSA) as the smart muscle. To realize the programmable integration of the two materials into a 3D configuration, a successive on-chip two-photon polymerization (TPP) strategy that enables structuring two photosensitive materials sequentially within a predesigned configuration was proposed. As a proof-of-concept, we demonstrate a pH-responsive spider microbot and a 3D smart micro-gripper that enables controllable grabbing and releasing. Our strategy provides a universal protocol for directly printing 3D microbots composed of multiple materials.

Recent progress in controlled nano/micro cracking as an alternative nano-patterning method for functional applications

Generally, cracking occurs for many reasons connected to uncertainties and to the non-uniformity resulting from intrinsic deficiencies in materials or the non-linearity of applied external (thermal, mechanical, etc.) stresses. However, recently, an increased level of effort has gone into analyzing the phenomenon of cracking and also into methods for controlling it. Sophisticated manipulation of cracking has yielded various cutting-edge technologies such as transparent conductors, mechanical sensors, microfluidics, and energy devices. In this paper, we present some of the recent progress that has been made in controlling cracking by giving an overview of the fabrication methods and working mechanisms used for various mediums. In addition, we discuss recent progress in the various applications of methods that use controlled cracking as an alternative to patterning tools.

Biomimetic Coating-free Superomniphobicity

Superomniphobic surfaces, which repel droplets of  polar and apolar liquids, are used for reducing frictional drag, packaging electronics and foods, and separation processes, among other applications. These surfaces exploit perfluorocarbons that are expensive, vulnurable to physical damage, and have a long persistence in the environment. Thus, new approaches for achieving superomniphobicity from common materials are desirable. In this context, microtextures comprising “mushroom-shaped” doubly reentrant pillars (DRPs) have been shown to repel drops of polar and apolar liquids in air irrespective of the surface make-up. However, it was recently demonstrated that DRPs get instantaneously infiltrated by the same liquids on submersion because while they can robustly prevent liquid imbibition from the top, they are vulnerable to lateral imbibition. Here, we remedy this weakness through bio-inspiration derived from cuticles of Dicyrtomina ornata, soil-dwelling bugs, that contain cuboidal secondary granules with mushroom-shaped caps on each face. Towards a proof-of-concept demonstration, we created a perimeter of biomimicking pillars around arrays of DRPs using a two-photon polymerization technique; another variation of this design with a short wall passing below the side caps was investigated. The resulting gas-entrapping microtextured surfaces (GEMS) robustly entrap air on submersion in wetting liquids, while also exhibiting superomniphobicity in air. To our knowledge, this is the first-ever microtexture that confers upon intrinsically wetting materials the ability to simultaneously exhibit superomniphobicity in air and robust entrapment of air on submersion. These findings should advance the rational design of coating-free surfaces that exhibit ultra-repellence (or superomniphobicity) towards liquids.

Liquid-Superrepellent Bioinspired Fibrillar Adhesives

Bioinspired elastomeric fibrillar surfaces have significant potential as reversible dry adhesives, but their adhesion performance is sensitive to the presence of liquids at the contact interface. Like their models in nature, many artificial mimics can effectively repel water, but fail when low-surface-tension liquids are introduced at the contact interface. A bioinspired fibrillar adhesive surface that is liquid-superrepellent even toward ultralow-surface-tension liquids while retaining its adhesive properties is proposed herein. This surface combines the effective adhesion principle of mushroom-shaped fibrillar arrays with liquid repellency based on double re-entrant fibril tip geometry. The adhesion performance of the proposed microfibril structures is retained even when low-surface-tension liquids are added to the contact interface. The extreme liquid repellency enables real-world applications of fibrillar adhesives for surfaces covered with water, oil, and other liquids. Moreover, fully elastomeric liquid-superrepellent surfaces are mechanically not brittle, highly robust against physical contact, and highly deformable and stretchable, which can increase the real-world uses of such antiwetting surfaces.

Digital Programming Graphene Oxide Liquid Crystalline Hybrid Hydrogel by Shearing Microlithography

Designing anisotropic architectures enables the creation of soft materials with rich properties and functions to artificially simulate the evolutionary diversity of biology. In the important liquid crystalline hybrid (LCH) hydrogels, free manipulation of liquid crystalline order in high accuracy and efficiency has been long pursued to design properties and functions but remains a challenge. Here, we realize digital programing LC order in graphene oxide LCH hydrogels in high size resolution (∼20 μm) and efficiency by using shearing microlithography. The localized shear-induced LC order organization is immobilized by cross-linking gelation, and we prepare graphene oxide LCH hydrogels with digital programmed patterns in a large area. The shearing order generates a vertical alignment of graphene oxide sheets in hydrogels and a considerable mechanical anisotropy controlled by the shearing angle and interval spacing. By diversely organizing geometry of LC order, the mechanical response behaviors of LCH hydrogels are designed to exhibit localized deformations, steered cracking, and programmable swelling actuations. Our work offers a versatile avenue to scalably digital program LCH hydrogels in a high efficiency and accuracy. The digital designed hydrogel promises wide uses in actuators, bioscaffolds, biomimetic materials, and soft designer materials.

Facile fabrication of superhydrophobic zinc coatings with corrosion resistance via an electrodeposition process

In this investigation, we demonstrated a controlled electrodeposition method by varying the current density to generate hierarchical structures of zinc (Zn) on a carbon steel surface, which serves as a hydrophobic and anticorrosion coating when further modified by stearic acid to form a covalently bonded layer that offers low surface energy.