Advances in the Fabrication of Superhydrophobic Polymeric Surfaces by Polymer Molding Processes

Abstract

Superhydrophobic materials are found in a suite of scientific and industrial applications, and given their broad potential use, there is great interest in facilitating their mass production. Although numerous methods have been used to produce superhydrophobic materials, only a few are capable of fabricating superhydrophobic surfaces and materials at an industrial scale. Techniques such as injection molding, compression molding, hot embossing, and polymer casting play an important role in the mass production of superhydrophobic polymer surfaces. This technical literature review summarizes recent advances in the polymer molding processes used to fabricate superhydrophobic materials. Here, we review replication methods and the materials that can be used by these approaches. We also evaluate the advantages and disadvantages of these methods and discuss the challenges of molding and demolding single-level structures (e.g., microstructures and nanostructures) and multilevel structures (e.g., micro-nanostructures, micromicrostructures, and micromicro-nanostructures), with a focus on superhydrophobic surfaces. We evaluate the relationship between structure geometry and the wettability of a surface, highlighting the effect of structure type and size in achieving the desired wettability. We then offer perspectives, discuss current limitations, and suggest required studies. This review aims to assist researchers in understanding the fundamentals related to the fabrication of patterned surfaces via polymer molding processes and offer avenues for the successful creation of superhydrophobic polymeric surfaces.

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“…36 Surface treatments oen refer to silane vapor deposition or liquid cast. [37][38][39][40][41] Surface roughness can be fabricated via colloidal lithography, 42 hot press, [43][44][45] mould, [46][47][48] and selective evaporation. 49 In addition, switchable hydrophilic and hydrophobic patterns have been designed for lotus-like self-cleaning capabilities.…”

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“…The use of hydrophobic polymers to fabricate superhydrophobic coatings (directly or as exterior coatings of roughened substrates), including HDPE, has been widely investigated in the literature. A common method has been the use of a hot molding/embossing technique to pattern polymers and induces surface roughness . Although successful as a nanofabrication technique, complex surface structures are typically quite difficult to obtain without the inclusion of a nanomaterial (particles, fibers, etc.)…”