Template-free scalable fabrication of linearly periodic microstructures by controlling ribbing defects phenomenon during forward roll coating

Linear periodic microstructures are of significant importance in various applications, including drag-reduction, biofouling, selfcleaning, and superhydrophobicity. However, practical applications of such surfaces require mass manufacturing techniques, which are highly limited. This study demonstrated a simple template-free scalable manufacturing technique to fabricate linearly periodic microstructure by controlling the ribbing defects in forward roll coating. A viscoelastic polymer nanocomposite with tailored properties was synthesized and utilized as the coating material. The ribbing instabilities were controlled with process parameters that resulted in variable periodicity of the linearly aligned microstructures with a spacing of 114 - 700 mu m. The microstructure arrangement also had a linear to random transition as the instabilities increased. The manufactured surface has a high Wenzel roughness factor that ranges from 1.6 to 3.6, which results in water contact angles of 128 degrees to 150 degrees. The linear microstructure films can have critical applications in the mass manufacturing of drag reduction surfaces. The high aspect-ratio microstructure films can also have applications in superhydrophobic, self-cleaning, anti-icing, and anti-biofouling surfaces. (C) 2022 Society of Manufacturing Engineers (SME). Published by Elsevier Ltd. All rights reserved.

Automated summary

This study presents a manufacturing technique for linear periodic microstructures and highlights their significance in various applications. The controlled ribbing defects in forward roll coating allow the fabrication of tailored microstructures, and the resulting surfaces have potential applications in drag reduction, superhydrophobicity, self-cleaning, and anti-biofouling surfaces.