Hierarchical structures with well-defined structural features of two or more distinct length scales are becoming increasingly important as a means to offer high-value functionality to man-made surfaces. In nature, the lotus leaf, butterfly wings, gecko's feet, and shark's skin each carry hierarchical structures that impart useful surface function: self-cleaning, structural color, reversible (chemical free) adhesion and drag reduction respectively. We have developed various methods to create hierarchical patterns in a facile, scalable manner. In particular, we demonstrate roll-to-roll (R2R) nanoimprint fabrication of functional broad band anti-reflective and self cleaning films at throughputs of 10 m/min. We report on progress made in various aspects: R2R equipment customization, mold fabrication, and hybrid nanoimprint process development. Importantly, we show successful creation of functional films with uniform high yield over continuous pattern fields of up to 200 mm x 270 mm. Further, we share novel methods of surface topographical patterning that allow us to create a diverse range of hierarchical structures out of nanoimprint compatible thermoplastic and cross-linked materials. These have demonstrated applications in controlled wetting and marine anti-fouling. 

Creating value added surfaces through nanopatterning and chemistry: Roll-to-Roll nanoimprinting and hybrid approaches for facile, large area surface patterning and functionalization

248th National Meeting (2014)

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