Ice-repellent coatings can have significant impact on global energy savings and improving safety in many infrastructures, transportation, and cooling systems. Recent efforts for developing ice-phobic surfaces have been mostly devoted to utilizing lotus-leaf-inspired superhydrophobic surfaces, yet these surfaces fail in high-humidity conditions due to water condensation and frost formation and even lead to increased ice adhesion due to a large surface area. We report a radically different type of ice-repellent material based on slippery, liquid-infused porous surfaces (SLIPS), where a stable, ultrasmooth, low-hysteresis lubricant overlayer is maintained by infusing a water-immiscible liquid into a nanostructured surface chemically functionalized to have a high affinity to the infiltrated liquid and lock it in place. We develop a direct fabrication method of SLIPS on industrially relevant metals, particularly aluminum, one of the most widely used lightweight structural materials. We demonstrate that SLIPS-coated Al surfaces not only suppress ice/frost accretion by effectively removing condensed moisture but also exhibit at least an order of magnitude lower ice adhesion than state-of-the-art materials. On the basis of a theoretical analysis followed by extensive icing/deicing experiments, we discuss special advantages of SLIPS as ice-repellent surfaces: highly reduced sliding droplet sizes resulting from the extremely low contact angle hysteresis. We show that our surfaces remain essentially frost-free in which any conventional materials accumulate ice. These results indicate that SLIPS is a promising candidate for developing robust anti-icing materials for broad applications, such as refrigeration, aviation, roofs, wires, outdoor signs, railings, and wind turbines.

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Lubricant-infused textured solid substrates are gaining remarkable interest as a new class of omni-repellent nonfouling materials and surface coatings. We investigated the effect of the length scale and hierarchy of the surface topography of the underlying substrates on their ability to retain the lubricant under high shear conditions, which is important for maintaining nonwetting properties under application-relevant conditions. By comparing the lubricant loss, contact angle hysteresis, and sliding angles for water and ethanol droplets on flat, microscale, nanoscale, and hierarchically textured surfaces subjected to various spinning rates (from 100 to 10,000 rpm), we show that lubricant-infused textured surfaces with uniform nanofeatures provide the most shear-tolerant liquid-repellent behavior, unlike lotus leaf-inspired superhydrophobic surfaces, which generally favor hierarchical structures for improved pressure stability and low contact angle hysteresis. On the basis of these findings, we present generalized, low-cost, and scalable methods to manufacture uniform or regionally patterned nanotextured coatings on arbitrary materials and complex shapes. After functionalization and lubrication, these coatings show robust, shear-tolerant omniphobic behavior, transparency, and nonfouling properties against highly contaminating media.

Inspired by the long-term effectiveness of living antifouling materials, we have developed a method for the self-replenishment of synthetic biofouling-release surfaces. These surfaces are created by either molding or directly embedding 3D vascular systems into polydimethylsiloxane (PDMS) and filling them with a silicone oil to generate a nontoxic oil-infused material. When replenished with silicone oil from an outside source, these materials are capable of self-lubrication and continuous renewal of the interfacial fouling-release layer. Under accelerated lubricant loss conditions, fully infused vascularized samples retained significantly more lubricant than equivalent nonvascularized controls. Tests of lubricant-infused PDMS in static cultures of the infectious bacteria Staphylococcus aureus and Escherichia coli as well as the green microalgae Botryococcus braunii, Chlamydomonas reinhardtii, Dunaliella salina, and Nannochloropsis oculata showed a significant reduction in biofilm adhesion compared to PDMS and glass controls containing no lubricant. Further experiments on vascularized versus nonvascularized samples that had been subjected to accelerated lubricant evaporation conditions for up to 48 h showed significantly less biofilm adherence on the vascularized surfaces. These results demonstrate the ability of an embedded lubricant-filled vascular network to improve the longevity of fouling-release surfaces.

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