Among numerous challenges to meet the rising global energy demand in a sustainable manner, improving phase change heat transfer has been at the forefront of engineering research for decades. The high heat transfer rates associated with phase change heat transfer are essential to energy and industry applications; but phase change is also inherently associated with poor thermodynamic efficiencies at low heat flux, and violent instabilities at high heat flux. Engineers have tried since the 1930's to fabricate solid surfaces that improve phase change heat transfer. The development of micro and nanotechnologies has made feasible the high-resolution control of surface texture and chemistry over length scales ranging from molecular levels to centimeters. This paper reviews the fabrication techniques available for metallic and siliconbased surfaces, considering sintered and polymeric coatings. The influence of such surfaces in multiphase processes of high practical interest, e.g. boiling, condensation, freezing, and the associated physical phenomena are reviewed. The case is made that while engineers are in principle able to manufacture surfaces with optimum nucleation or thermofluid transport characteristics, more theoretical and experimental efforts are needed to guide the design and cost-effective fabrication of surfaces that not only satisfy the existing technological needs, but also catalyze new discoveries.

With recent advances in micro-and nanofabrication, superhydrophilic and superhydrophobic surfaces have been developed. The statics and dynamics of fluids on these surfaces have been well characterized. However, few investigations have been made into the potential of these surfaces to control and enhance other transport phenomena. In this article, we characterize pool boiling on surfaces with wettabilities varied from superhydrophobic to superhydrophilic, and provide nucleation measurements. The most interesting result of our measurements is that the largest heat transfer coefficients are reached not on surfaces with spatially uniform wettability, but on biphilic surfaces, which juxtapose hydrophilic and hydrophobic regions. We develop an analytical model that describes how biphilic surfaces effectively manage the vapor and liquid transport, delaying critical heat flux and maximizing the heat transfer coefficient. Finally, we manufacture and test the first superbiphilic surfaces (juxtaposing superhydrophobic and superhydrophilic regions), which show exceptional performance in pool boiling, combining high critical heat fluxes over 100 W/cm

We demonstrate that smooth and flat surfaces combining hydrophilic and hydrophobic patterns improve pool boiling performance. Compared to a hydrophilic surface with 7º wetting angle, the measured critical heat flux and heat transfer coefficients of the enhanced surfaces are up to respectively 65 and 100% higher. Different networks combining hydrophilic and hydrophobic regions are characterized. While all tested networks enhance the heat transfer coefficient, large enhancements of critical heat flux are typically found for hydrophilic networks featuring hydrophobic islands. Hydrophilic networks indeed are shown to prevent the formation of an insulating vapor layer.

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In this study we present the fabrication of multilayer microneedles with circular obelisk and beveled-circular obelisk geometries, which have potential applications in implantable drug delivery devices. Micro-milling was adopted as an environmental-friendly and cost-effective way to fabricate primary metal microneedle masters. Polylactic acid (PLA) microneedles with sharp tips were then obtained by micromolding followed by oxygen plasma etching and used for preparing polydimethylsiloxane (PDMS) microneedle molds. A spray deposition process was employed for microneedle fabrication to facilitate the formation of multilayer microneedles while helping in maintenance of drug stability. Multilayer microneedles were successfully formed by sequential spraying of poly(lactic-co-glycolic acid) (PLGA) and polyvinylpyrrolidone (PVP) solutions into the mold. The fabricated PLGA-PVP multilayer microneedles penetrated the pig cadaver skin without breakage and released dyes in the skin at different rates, which reveals the potential for implantable microneedles enabling controlled release. Mechanical testing demonstrated that the obelisk-shaped microneedles were mechanically stronger than a pyramid-shaped microneedle and suggested that strong adhesion between PLGA and PVP layers was achieved as well. Structural stability and functionality of a model drug, horseradish peroxidase (HRP), upon spray deposition was examined using circular dichroism (CD) spectroscopy and enzyme activity assay. HRP retained its secondary structure and activity in PVP, whereas HRP in PLGA showed structural changes and reduced activity. Combination of micro-milling and spray deposition would be an attractive way of fabricating drug-containing polymer microneedles with various geometries while reducing prototyping time and process-induced drug instability.