The past decade saw a drastic increase in the understanding and applications of superhydrophobic surfaces (SHSs). Water beads up and effortlessly rolls off a SHS due to its combination of low surface energy and texture. Whether being used for drag reduction, stain repellency, self-cleaning, fog harvesting, or heat transfer applications (to name a few), the durability of a SHS is critically important. Although a handful of purportedly durable SHSs have been reported, there are still no criteria available for systematically designing a durable SHS. In the first part of this work, we discuss two new design parameters that can be used to develop mechanically durable SHSs via the spray coating of different binders and fillers. These parameters aid in the rational selection of material components and allow one to predict the capillary resistance to wetting of any SHS from a simple topographical analysis. We show that not all combinations of sprayable components generate SHSs, and mechanically durable components do not necessarily generate mechanically durable SHSs. Moreover, even the most durable SHSs can eventually become damaged. In the second part, utilizing our new parameters, we design and fabricate physically and chemically self-healing SHSs. The most promising surface is fabricated from a fluorinated polyurethane elastomer (FPU) and the extremely hydrophobic small molecule 1H,1H,2H,2H-heptadecafluorodecyl polyhedral oligomeric silsesquioxane (F-POSS). A sprayed FPU/F-POSS surface can recover its superhydrophobicity even after being abraded, scratched, burned, plasma-cleaned, flattened, sonicated, and chemically attacked.Keywords: coatings; durability; self-healing; superhydrophobic; wettability;

Open-channel microfluidic devices have shown great potential in achieving a high degree of fluid control, at relatively low-cost, while enabling the opportunity for rapid fabrication. However, thus far, work in open channel microfluidics has largely focused on controlling the flow of water or other aqueous solutions. In this work we present new open channel microfluidic devices based on surfaces with patterned wettabilty that are capable of controlling the flow of virtually all high and low surface tension liquids. The fabricated open channel devices are capable of constraining a variety of low surface tension oils at high enough flow rates to enable, for the first time, water-in-oil microfluidic emulsification in an open channel device. By changing the flow rates for both the aqueous (dispersed) and organic (continuous) phases, we show that it is possible to vary the size of the emulsified droplets produced in the open channel device. Finally, we utilized the fabricated devices to synthesize relatively monodisperse, hydrogel microparticles that could incorporate a drug molecule. We also investigated the drug release characteristics of the fabricated particles.

Superomniphobic surfaces display contact angles of θ* > 150° and low contact angle hysteresis with virtually all high and low surface tension liquids. The introduction of hierarchical scales of texture can increase the contact angles and decrease the contact angle hysteresis of superomniphobic surfaces by reducing the solid–liquid contact area. Thus far, it has not been possible to fabricate superomniphobic surfaces with three or more hierarchical scales of texture where the size, spacing, and angular orientation of features within each scale of texture can be independently varied and controlled. Here, we report a method for tunable control of geometry in hyperbranched ZnO nanowire (NW) structures, which in turn enables the rational design and fabrication of superomniphobic surfaces. Branched NWs with tunable density and orientation were grown via a sequential hydrothermal process, in which atomic layer deposition was used for NW seeding, disruption of epitaxy, and selective blocking of NW nucleation. This approach allows for the rational design and optimization of three-level hierarchical structures, in which the geometric parameters of each level of hierarchy can be individually controlled. We demonstrate the coupled relationships between geometry and contact angles for a variety of liquids, which is supported by mathematical models. The highest performing superomniphobic surface was designed with three levels of hierarchy and achieved the following advancing/receding contact angles with water 172°/170°, hexadecane 166°/156°, octane 162°/145°, and heptane 160°/130°.Keywords: atomic layer deposition; hierarchical; materials by design; nanowire; superhydrophobic; superomniphobic;

Precise control over the geometry and chemistry of multiphasic particles is of significant importance for a wide range of applications. In this work, we have developed one of the simplest methodologies for fabricating monodisperse, multiphasic micro- and nanoparticles possessing almost any composition, projected shape, modulus, and dimensions as small as 25 nm. The synthesis methodology involves the fabrication of a nonwettable surface patterned with monodisperse, wettable domains of different sizes and shapes. When such patterned templates are dip-coated with polymer solutions or particle dispersions, the liquids, and consequently the polymer or the particles, preferentially self-assemble within the wettable domains. Utilizing this phenomenon, we fabricate multiphasic assemblies with precisely controlled geometry and composition through multiple, layered depositions of polymers and/or particles within the patterned domains. Upon releasing these multiphasic assemblies from the template using a sacrificial layer, we obtain multiphasic particles. The templates can then be readily reused (over 20 times in our experiments) for fabricating a new batch of particles, enabling a rapid, inexpensive, and easily reproducible method for large-scale manufacturing of multiphasic particles.Keywords: multiphasic particles; particles fabrication; patterned surfaces; precise patterning; wettability;

We fabricate high-efficiency, ultrathin (∼12 μm), flexible, upgraded metallurgical-grade polycrystalline silicon solar cells with multiple plasmonic layers precisely positioned on top of the cell to dramatically increase light absorption. This scalable approach increases the optical absorptivity of our solar cells over a broad range of wavelengths, and they achieve efficiencies η ≈ 11%. Detailed studies on the electrical and optical properties of the developed solar cells elucidate the light absorption contribution of each individual plasmonic layer. Finite-difference time-domain simulations were also performed to yield further insights into the obtained results. We anticipate that the findings from this work will provide useful design considerations for fabricating a range of different solar cell systems.

Surfaces that display contact angles >150° along with low contact angle hysteresis with essentially all high and low surface tension liquids, including water, oils and alcohols, are known as superomniphobic surfaces. Such surfaces have a range of commercial applications, including self-cleaning, non-fouling, stain-free clothing, drag reduction, corrosion prevention and separation of liquids. Such surfaces have thus generated immense academic and industrial interest in recent years. In this review, we discuss the systematic design of superomniphobic surfaces. In particular, we discuss the significance of surface energy, roughness and the critical role of re-entrant texture in obtaining the so-called Cassie–Baxter state with low surface tension liquids. We also discuss how hierarchical scales of texture can yield high contact angles and decrease the contact angle hysteresis of superomniphobic surfaces by reducing the solid–liquid contact area. On the basis of this understanding, we discuss dimensionless design parameters that allow for the systematic design of superomniphobic surfaces. We also review the current literature on superomniphobic surfaces, paying particular attention to surfaces that demonstrate good mechanical, chemical and radiation durability—traits that are essential for any commercial application of superomniphobic surfaces. Finally, we conclude by identifying the unresolved challenges in the fabrication of durable superomniphobic surfaces and highlight the future needs in the field.

Multiple oil spill disasters over the last few years have highlighted the challenges of effective oil–water separation. The separation of oil–water micro- and nano-emulsions (emulsions with dispersed droplet sizes in the micro- or nano-meter range) can be particularly difficult.1, 2 Shi et al.3 from the Chinese Academy of Sciences in Suzhou and Beijing have now developed ultrathin carbon nanotube membranes that can separate a wide range of oil–water micro- and nano-emulsions with separation efficiency >99.9%. Perhaps more significantly, the separation fluxes are 2–3 orders of magnitude higher than those obtained with current commercially available separation membranes.Membrane-based oil–water separation technologies are attractive for emulsion separation because they are energy-efficient, cost-effective and applicable across a wide range of industrial effluents. One factor that governs the flux of the permeate during separation is the membrane thickness. This separation flux is inversely proportional to the thickness of the membrane, that is, thinner membranes provide a higher separation flux. The thickness of commercially available separation membranes can vary between tens and hundreds of micrometers. In comparison, Shi et al.3 developed free-standing single-walled carbon nanotube network films that can be as thin as 30 nanometers. These films are hydrophobic (water-repellent with water contact angles >90°) and superoleophilic (extremely oil-absorbent with oil contact angles of 0°). Consequently, they allow oil to easily permeate through, while simultaneously preventing the permeation of water. Multiple groups have previously developed hydrophobic and oleophilic surfaces,4, 5 however the membranes developed by Shi et al.3 are perhaps the thinnest to date. By utilizing these ultrathin membranes in a separation apparatus (Figure 1a), Shi et al.3 demonstrated the separation of various oil–water emulsions with fluxes between 104–105  L m−2 h−1 per bar, which are 2–3 orders of magnitude higher than the fluxes typically obtained with commercial separation membranes.Their separation apparatus consisted of a filtration cell (ultrathin carbon nanotube membrane placed on a ceramic membrane) sandwiched between two glass beakers (Figure 1a). When a water-in-oil emulsion was added above the filtration cell, and a transmembrane pressure applied, oil permeated through the membrane, while water was retained above the membrane. In this manner, a series of water-in-oil emulsions, including surfactant-free water-in-petroleum ether, water-in-isooctane, water-in-cyclohexane microemulsions (Figure 1b) and span80-stabilized water-in-toluene nanoemulsions (Figure 1c), were separated with a separation efficiency >99.9%.The chemical stability of carbon nanotubes against a range of acids and bases allows these membranes to separate a broad range of water-in-oil emulsions. One potential limitation of the membranes is that they can get fouled by the oil present within the emulsions, and therefore have to be periodically cleaned by passing ethanol. Further research on effectively separating commercially relevant emulsions and oil-in-water emulsions using these membranes, as well as, improving their anti-fouling properties can make these membranes even more attractive for industrial deployment.

We present a thin film (<20 μm) solar cell based on upgraded metallurgical-grade polycrystalline Si that utilizes silver nanoparticles atop silicon nanopillars created by block copolymer nanolithography to enhance light absorption and increase cell efficiency η > 8%. In addition, the solar cells are flexible and semitransparent so as to reduce balance of systems costs and open new applications for conformable solar cell arrays on a variety of surfaces. Detailed studies on the optical and electrical properties of the resulting solar cells suggest that both antireflective and light-trapping mechanisms are key to the enhanced efficiency.

Superomniphobic surfaces display contact angles >150° and low contact angle hysteresis with essentially all contacting liquids. In this work, we report surfaces that display superomniphobicity with a range of different non-Newtonian liquids, in addition to superomniphobicity with a wide range of Newtonian liquids. Our surfaces possess hierarchical scales of re-entrant texture that significantly reduce the solid–liquid contact area. Virtually all liquids including concentrated organic and inorganic acids, bases, and solvents, as well as viscoelastic polymer solutions, can easily roll off and bounce on our surfaces. Consequently, they serve as effective chemical shields against virtually all liquids—organic or inorganic, polar or nonpolar, Newtonian or non-Newtonian.