Considerable attention is currently being devoted less to the question of whether it is possible to produce superhydrophobic polymer surfaces than to just how robust they can be made. The present study demonstrates a new route for improving the mechanical durability of water-repellent structured surfaces. The key idea is the protection of fragile fine-scale surface topographies against wear by larger scale sacrificial micropillars. A variety of surface patterns was manufactured on polypropylene using a microstructuring technique and injection molding. The surfaces subjected to mechanical pressure and abrasive wear were characterized by water contact and sliding angle measurements as well as by scanning electron microscopy and roughness analysis based on optical profilometry. The superhydrophobic polypropylene surfaces with protective structures were found to maintain their wetting properties in mechanical compression up to 20 MPa and in abrasive wear tests up to 120 kPa. For durable properties, the optimal surface density of the protective pillars was found to be about 15%. The present approach to the production of water-repellent polymer surfaces provides the advantages of mass production and mechanical robustness with practical applications of structurally functionalized surfaces.

Nature's functional surfaces are typically hierarchical multiscale structures. There are several techniques for producing such artificial structures on polymers but their mass production is not straightforward. We present here a simple and versatile method for manufacturing hierarchical multiscale polymer surface patterns. The microroughening technique permits the single-step production of multilevel three-dimensional surface architectures in a mechanically durable nickel mold. The molding technique is suitable for area-controlled fabrication of structures with various geometrical shapes on smooth and curved surfaces. The mold structures were transferred to polypropylene surfaces by means of injection molding. The fabricated surface structures were characterized by using a filtered power spectral density method which facilitated a quantitative study of the roughness distributions at different length scales of structure periodicities. Analysis showed that the microroughening technique is an appropriate tool for controlled production of surface roughness at a micro-nanometer scale. Roughness distribution values can be used for predicting surface structure-related properties such as wetting, and the distributions can also be simulated without an experimental preparation process. The work presents a suitable approach for mass production of hierarchical polymer surfaces at different length scales and provides a new route for designing surface structures with tunable wetting properties.

Abstract. In this paper, the results of exploiting self-organized sub-micron polystyrene (PS) wrinkle patterns possessing random orientation, in preparation of a nickel stamp for hot embossing purposes, are presented. Self-organized patterns were prepared employing a method in which a stiff cross-linked capping layer on the topmost part of the soft polystyrene layer was created by using reactive ion etching (RIE) device with mild conditions and argon as a process gas, and the wrinkle formation was initiated thermally. Different surface patternings were obtained using silicon and stainless steel (SST) wafers as substrates. Prepared Ni-stamps were employed in hot embossing of polycarbonate (PC) and cyclo-olefin polymer (COP) films, using a nano-imprinting process. The replication quality of the self-organized wrinkle structures in PC and COP films was monitored by comparing the shape and dimensions of the original and final surface structures. The hot embossed sub-micron scale features, originally formed on stainless steel substrate, were found to have influence on the optical properties of the PC and COP films by lowering their reflectances.