Rectangle-capped and tilted micropillar array for enhanced anisotropic anti-shearing in biomimetic adhesion

Decoding the mechanical characteristics of the human anterior cruciate ligament entheses through graduated mineralization interfaces

The anterior cruciate ligament is anchored to the femur and tibia via specialized interfaces known as entheses. These play a critical role in ligament homeostasis and joint stability by transferring forces, varying in magnitude and direction between structurally and functionally dissimilar tissues. However, the precise structural and mechanical characteristics underlying the femoral and tibial entheses and their intricate interplay remain elusive. In this study, two thin-graduated mineralization regions in the femoral enthesis (~21 μm) and tibial enthesis (~14 μm) are identified, both exhibiting distinct biomolecular compositions and mineral assembly patterns. Notably, the femoral enthesis interface exhibits progressively maturing hydroxyapatites, whereas the mineral at the tibial enthesis interface region transitions from amorphous calcium phosphate to hydroxyapatites with increasing crystallinity. Proteomics results reveal that Matrix Gla protein uniquely enriched at the tibial enthesis interface, may stabilize amorphous calcium phosphate, while C-type lectin domain containing 11 A, enriched at the femoral enthesis interface, could facilitate the interface mineralization. Moreover, the finite element analysis indicates that the femoral enthesis model exhibited higher resistance to shearing, whereas the tibial enthesis model contributes to tensile resistance, suggesting that the discrepancy in biomolecular expression and the corresponding mineral assembly heterogeneities collectively contribute to the superior mechanical properties of both the femoral enthesis and tibial enthesis models. These findings provide novel perspectives on the structure-function relationships of anterior cruciate ligament entheses, paving the way for improved management of anterior cruciate ligament injury and regeneration.

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.

Interaction of a non-axisymmetric artificial single spatula with rough surfaces

Hair-like attachment structures are frequently used by animals to create stable contact with rough surfaces. Previous studies focused primarily on axisymmetric biomimetic models of artificial spatulas, such as those with a mushroom-shaped and cylinder-shaped geometry, in order to simulate the so-called gecko effect. Here, two geometric prototypes of artificial adhesive structures with non-axisymmetric properties were designed. The investigation of the prototype's interactions with rough surfaces was carried out using the finite element software ABAQUS. Under increasing vertical displacement, the effect of asperity size on the contact pressure evolution of the spatula was investigated. It has been demonstrated that the contact behaviour is greatly affected by the flexibility of the spatula, which is caused by its variable thickness. The thinner spatula shows a higher nominal contact area and attaches more strongly to various rough surfaces. Although a thicker spatula is more susceptible to the 'leverage' phenomenon, which occurs when excessively applied displacements prematurely reduce the nominal contact area, it obtains the ability to regulate attachment during unidirectional loading. Two non-axisymmetric prototypes provide different design concepts for the artificial adhesives. It is hoped that this study will provide fresh viewpoints and innovations that contribute to the development of biologically inspired adhesives.

Multiscale Synergistic Gecko-Inspired Adhesive for Stable Adhesion under Varying Preload and Surface Roughness

Inspired by geckos, fibrillar microstructures hold great promise as controllable and reversible adhesives in the engineering field. However, enhancing the adhesion strength and stability of gecko-inspired adhesives (GIAs) under complex real-world contact conditions, such as rough surfaces and varying force fields, is crucial for its commercialization, yet further research is lacking. Here, we propose a hierarchically designed GIA, which features a silicone foam (SF) backing layer and a film-terminated fibrillar microstructure under a subtle multiscale design. This structure has been proven to have a "multiscale synergistic effect", allowing the material to maintain strong and stable adhesion to surfaces with changing normal pressures and roughness. Specifically, under a high load, the adhesive strength is 2 times more than that of conventional GIA, and it is 1.5 times stronger on rough surfaces compared to conventional GIA. Under high pressure and high surface roughness simultaneously, the adhesive strength is 3.3 times higher compared to conventional GIA. Our research demonstrates that the synergistic effect of multiscale biomimetic adhesion structures is highly effective in enhancing the adhesive strength of GIA under some harsh contact conditions.

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.

Gecko-Inspired Adhesive Mechanisms and Adhesives for Robots—A Review

Small living organisms such as lizards possess naturally built functional surface textures that enable them to walk or climb on versatile surface topographies. Bio-mimicking the surface characteristics of these geckos has enormous potential to improve the accessibility of modern robotics. Therefore, gecko-inspired adhesives have significant industrial applications, including robotic endoscopy, bio-medical cleaning, medical bandage tapes, rock climbing adhesives, tissue adhesives, etc. As a result, synthetic adhesives have been developed by researchers, in addition to dry fibrillary adhesives, elastomeric adhesives, electrostatic adhesives, and thermoplastic adhesives. All these adhesives represent significant contributions towards robotic grippers and gloves, depending on the nature of the application. However, these adhesives often exhibit limitations in the form of fouling, wear, and tear, which restrict their functionalities and load-carrying capabilities in the natural environment. Therefore, it is essential to summarize the state of the art attributes of contemporary studies to extend the ongoing work in this field. This review summarizes different adhesion mechanisms involving gecko-inspired adhesives and attempts to explain the parameters and limitations which have impacts on adhesion. Additionally, different novel adhesive fabrication techniques such as replica molding, 3D direct laser writing, dip transfer processing, fused deposition modeling, and digital light processing are encapsulated.

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.

Effects of loading and unloading control parameters on adhesive performance for biomimetic controllable adhesive with wedge-shaped microstructures

The adhesive performance of biomimetic controllable adhesive based on wedge-shaped microstructures is affected by some relevant control parameters in the process of loading and unloading. An appropriate selection of these control parameters is of great significance for its effective application. However, little research has concentratively and comprehensively explored these control parameters. In order to make up for the shortcoming, this study systematically explored the macroscopic adhesive performance of the self-developed wedge-shaped microstructures under different loading and unloading control parameters. The results show that preloading depth and tangential dragging distance have a positive effect on the adhesive performance, while preloading angle and peeling angle have a negative effect on the adhesive performance. Specifically, a low preloading angle can weaken the normal preloading force under the same preloading depth, thereby improving the preloading benefit; the application of tangential dragging distance can also induce the normal preloading force generated in the preloading stage to change the adhesion, so as to stimulate more adhesion. Based on the interactive analysis of these control parameters, it can be sure that applying a moderate normal preloading force and a larger tangential dragging distance to the wedge-shaped microstructures at low preloading angle not only makes the wedge-shaped microstructures possess better adhesive capacity, but also can obtain a good preloading benefit. In addition, the promotion effect of a low peeling angle on the adhesive performance also implies that a higher peeling angle should be used to realize the easy detachment of the adhesive interface. The first concentrative and comprehensive investigation of the relevant control parameters of wedge-shaped microstructures lays the foundation for designing a climbing robot or adhesive gripper based on the wedge-shaped microstructures, and also provides guidance for formulating the corresponding control strategies.

Forcing the issue: testing gecko-inspired adhesives

Materials are traditionally tested either by imposing controlled displacements and measuring the corresponding forces, or by imposing controlled forces. The first of these approaches is more common because it is straightforward to control the displacements of a stiff apparatus and, if the material suddenly fails, little energy is released. However, when testing gecko-inspired adhesives, an applied force paradigm is closer to how the adhesives are loaded in practice. Moreover, we demonstrate that the controlled displacement paradigm can lead to artefacts in the assumed behaviour unless the imposed loading trajectory precisely matches the deflections that would occur in applications. We present the design of a controlled-force system and protocol for testing directional gecko-inspired adhesives and show that results obtained with it are in some cases substantially different from those with controlled-displacement testing. An advantage of the controlled-force testing approach is that it allows accurate generation of adhesive limit curves without prior knowledge of the expected behaviour of the material or the loading details associated with practical applications.

An electrically active gecko-effect soft gripper under a low voltage by mimicking gecko's adhesive structures and toe muscles

With the combination of the passive adhesion generated by micro/nano-structures at their feet and the active mechanical stimulus of their toe muscles, geckos can stably walk on vertical walls and horizontal ceilings. Inspired by such stimuli-responsive systems in nature, an active adhesive soft gripper stimulated by low voltage (usually ≤6 V), consisting of a passive mushroom-like adhesive structure and an electrically active liquid crystal elastomer working as toe muscles, is proposed in this study. Through voltage on/off switching, reversible deformation can be generated for switchable adhesion, where high adhesion can be achieved under the action of a preload force accompanied by a 0 V voltage and low adhesion can be obtained under an exerted voltage. This gecko-inspired soft gripper was tested and found to be successful as a transport device for gripping/releasing objects with different features, such as a glass ball, a sample bottle, and a steel weight. To the best of our knowledge, the present study is the first to propose an electrically active gecko-inspired soft gripper for transferring objects with different surfaces by the control of low voltage, processing great application potential in industrial lines and daily life and providing a novel perspective on soft gripper design.

Spatially variant microstructured adhesive with one-way friction

Surface microstructures in nature enable diverse and intriguing properties, from the iridescence of butterfly wings to the hydrophobicity of lotus leaves to the controllable adhesion of gecko toes. Many artificial analogues exist; however, there is a key characteristic of the natural materials that is largely absent from the synthetic versions-spatial variation. Here we show that exploiting spatial variation in the design of one class of synthetic microstructure, gecko-inspired adhesives, enables one-way friction, an intriguing property of natural gecko adhesive. When loaded along a surface in the preferred direction, our adhesive material supports forces 100 times larger than when loaded in the reverse direction, representing an asymmetry significantly larger than demonstrated in spatially uniform adhesives. Our study suggests that spatial variation has the potential to advance artificial microstructures, helping to close the gap between synthetic and natural materials.

Enhancement of Interfacial Adhesion Using Micro/Nanoscale Hierarchical Cilia for Randomly Accessible Membrane-Type Electronic Devices

The recent technology of transfer printing using various membrane-type flexible/stretchable electronic devices can provide electronic functions to desirable objects where direct device fabrication is difficult. However, if the target surfaces are rough and complex, the capability of accommodating surface mismatches for reliable interfacial adhesion remains a challenge. Here, we demonstrate that newly designed nanotubular cilia (NTCs), vertically aligned underneath a polyimide substrate, significantly enhance interfacial adhesion. The tubular structure easily undergoes flattening and wrapping motions to provide a large conformal contact area, and the synergetic effect of the assembled cilia strengthens the overall adhesion. Furthermore, the hierarchical structure consisting of radially spread film-type cilia combined with vertically aligned NTCs in specific regions enables successful transfer printing onto very challenging surfaces such as stone, bark, and textiles. Finally, we successfully transferred a temperature sensor onto an eggshell and indium gallium zinc oxide-based transistors onto a stone with no electrical failure.

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.

Superhydrophobic Microporous Substrates via Photocuring: Coupling Optical Pattern Formation to Phase Separation for Process-Tunable Pore Architectures

We present a new approach to synthesize microporous surfaces through the combination of photopolymerization-induced phase separation and light pattern formation in photopolymer-solvent mixtures. The mixtures are irradiated with a wide-area light pattern consisting of high and low intensity regions. This light pattern undergoes self-focusing and filamentation, thereby preserving its spatial profile through the mixture. Over the course of irradiation, the mixture undergoes phase separation, with the polymer and solvent located in the bright and dark regions of the light profile, respectively, to produce a binary phase morphology with a congruent arrangement as the optical pattern. A congruently arranged microporous structure is attained upon solvent removal. The microporous surface structure can be varied by changing the irradiating light profile via photomask design. The porous architecture can be further tuned through the relative weight fractions of photopolymer and solvent in the mixture, resulting in porosities ranging from those with discrete and uniform pore sizes to hierarchical pore distributions. All surfaces become superhydrophobic (water contact angles >150°) when spray-coated with a thin layer of polytetrafluoroethylene nanoparticles. The water contact angles can be enhanced by changing the surface porosity via the processing conditions. This is a scalable and tunable approach to precisely control microporous surface structure in thin films to create functional surfaces and antiwetting coatings.

Discretely Supported Dry Adhesive Film Inspired by Biological Bending Behavior for Enhanced Performance on a Rough Surface

Biologically inspired dry adhesion has recently become a research hot topic because of its practical significance in scientific research and instrumental technology. Yet, most of the current studies merely focus on borrowing the concept from some finer biological contact elements but lose sight of the foundation ones that play an equally important role in the adhesion functionality. Inspired by the bending behavior of the flexible foundation element of a gecko (lamellar skin) in attachment motion, in this study, a new type of dry adhesive structure was proposed, wherein a mushroom-shaped micropillar array behaving as a strongly adhesive layer was engineered on a discretely supported thin film. We experimentally observed and analytically modeled the structural deformation and found that the energy penalty could be largely reduced because of the partial shift from pillar bending to film bending. Such behavior is very analogous in functionality to the lamellar skin in a gecko's pads and is helpful in effectively limiting the damage of the contact interface, thus generating enhanced adhesion even on a rough surface.

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.

Switchable Dry Adhesion with Step-like Micropillars and Controllable Interfacial Contact

Dry adhesives have attracted much attention because of their repeatable and reversible attachment. Many research groups have made fruitful achievements in fabricating and designing various dry adhesives. However, most of these studies focus on imitating bioinspired geometry to achieve this smart adhesion, neglecting the contact interface control through their peeling motion. Here, we present an alternative design to achieve this switchable adhesion on the basis of controlling contact areas. This unique design includes micropillars array with large overhanging caps and a "step" located at the center line of the cap. When dragging the pillars in the direction of the upper surface of the step, the lower surface is brought into contact, rapidly yielding stronger adhesion (switched-on state). Alternatively, when dragging the pillars in the direction of the lower surface of the step, the contact areas decrease sharply, leading to weak adhesion (switched-off state). Such switchable property under strong adhesion force is exactly what many practical applications need, and the ability to achieve this property by controlling the adhesion area size presented here opens a new way to dry adhesives design.