Nature has developed reversibly adhesive surfaces whose stickiness has attracted much research attention over the last decade. The central lesson from nature is that “patterned” or “fibrillar” surfaces can produce higher adhesion forces to flat and rough substrates than smooth surfaces. This paper critically examines the principles behind fibrillar adhesion from a contact mechanics perspective, where much progress has been made in recent years. The benefits derived from “contact splitting” into fibrils are separated into extrinsic/intrinsic contributions from fibril deformation, adaptability to rough surfaces, size effects due to surface‐to‐volume ratio, uniformity of stress distribution, and defect‐controlled adhesion. Another section covers essential considerations for reliable and reproducible adhesion testing, where better standardization is still required. It is argued that, in view of the large number of parameters, a thorough understanding of adhesion effects is required to enable the fabrication of reliable adhesive surfaces based on biological examples.

The extraordinary adherence and climbing agility of geckos on rough surfaces has been attributed to the multiscale hierarchical structures on their feet. Hundreds of thousands of elastic hairs called setae, each of which split into several spatulae, create a large number of contact points that generate substantial adhesion through van der Waals interactions. The hierarchical architecture provides increased structural compliance on surfaces with roughness features ranging from micrometers to millimeters. We review synthetic adhesion surfaces that mimic the naturally occurring hierarchy with an emphasis on microfabrication strategies, material choice and the adhesive performance achieved.

To mimic the adhesive effects of gecko toes, artificial surfaces have been manufactured recently using polydimethylsiloxanes (PDMS). However, the effects of repeated contacts on the adhesive properties remain largely unexplored. In this paper we report on the effect of repeated pull‐off force measurements on the adhesion behavior of PDMS (polymer kit Sylgard 184, Dow Corning) tested with a borosilicate glass probe. A decrease in pull‐off force with increase in number of test cycles is found until a plateau is reached. The initial value and the rate of change in pull‐off force strongly depend on the sample preparation procedure, including curing time and cross‐linking. It is proposed that the behavior is due to steady coverage of the probe with free oligomers. The results are crucial for developing reusable, durable, and residue‐free bioinspired adhesives.

Suction based attachment systems for pick and place handling of fragile objects like glass plates or optical lenses are energy-consuming and noisy and fail at reduced air pressure, which is essential, e.g., in chemical and physical vapor deposition processes. Recently, an alternative approach toward reversible adhesion of sensitive objects based on bioinspired dry adhesive structures has emerged. There, the switching in adhesion is achieved by a reversible buckling of adhesive pillar structures. In this study, we demonstrate that these adhesives are capable of switching adhesion not only in ambient air conditions but also in vacuum. Our bioinspired patterned adhesive with an area of 1 cm2 provided an adhesion force of 2.6 N ± 0.2 N in air, which was reduced to 1.9 N ± 0.2 N if measured in vacuum. Detachment was induced by buckling of the structures due to a high compressive preload and occurred, independent of air pressure, at approximately 0.9 N ± 0.1 N. The switch in adhesion was observed at a compressive preload between 5.6 and 6.0 N and was independent of air pressure. The difference between maximum adhesion force and adhesion force after buckling gives a reasonable window of operation for pick and place processes. High reversibility of the switching behavior is shown over 50 cycles in air and in vacuum, making the bioinspired switchable adhesive applicable for handling operations of fragile objects.

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A novel switchable adhesive, inspired by the gecko's fibrillar dry attachment system, is introduced. It consists of a patterned surface with an array of mushroom-shaped pillars having two distinct heights. The different pillar heights allow control of the pull-off force in two steps by application of a low and a high preload. For low preload, only the long pillars form contact, resulting in a low pull-off force. At higher preload, all pillars form contact, resulting in high pull-off force. Even further loading leads to buckling induced detachment of the pillars which corresponds to extremely low pull-off force. To achieve the respective samples a new fabrication method called double inking is developed, to achieve multiple-height pillar structures. The adhesion performance of the two-step switchable adhesive is analysed at varying preload and for different pillar aspect ratios and height relations. Finally, the deformation behavior of the samples is investigated by in situ monitoring.

A switchable dry adhesive based on a nickel–titanium (NiTi) shape-memory alloy with an adhesive silicone rubber surface has been developed. Although several studies investigate micropatterned, bioinspired adhesive surfaces, very few focus on reversible adhesion. The system here is based on the indentation-induced two-way shape-memory effect in NiTi alloys. NiTi is trained by mechanical deformation through indentation and grinding to elicit a temperature-induced switchable topography with protrusions at high temperature and a flat surface at low temperature. The trained surfaces are coated with either a smooth or a patterned adhesive polydimethylsiloxane (PDMS) layer, resulting in a temperature-induced switchable surface, used for dry adhesion. Adhesion tests show that the temperature-induced topographical change of the NiTi influences the adhesive performance of the hybrid system. For samples with a smooth PDMS layer the transition from flat to structured state reduces adhesion by 56%, and for samples with a micropatterned PDMS layer adhesion is switchable by nearly 100%. Both hybrid systems reveal strong reversibility related to the NiTi martensitic phase transformation, allowing repeated switching between an adhesive and a nonadhesive state. These effects have been discussed in terms of reversible changes in contact area and varying tilt angles of the pillars with respect to the substrate surface.