Effects of Stiff Film Pattern Geometry on Surface Buckling Instabilities of Elastic Bilayers

Buckling instabilities-such as wrinkling and creasing-of micropatterned elastic surfaces play important roles in applications, including flexible electronics and microfluidics. In many cases, the spatial dimensions associated with the imposed pattern can compete with the natural length scale of the surface instabilities (e.g., the wrinkle wavelength), leading to a rich array of surface buckling behaviors. In this paper, we consider elastic bilayers consisting of a spatially patterned stiff film supported on a continuous and planar soft substrate. Through a combination of experimental and computational analyses, we find that three surface instability modes-wrinkling, Euler buckling, and rigid rotation-are observed for the stiff material patterns, depending on the in-plane dimensions of the film compared to the natural wrinkle wavelength, while the intervening soft regions undergo a creasing instability. The interplay between these instabilities leads to a variety of surface structures as a function of the pattern geometry and applied compressive strain, in many cases yielding contact between neighboring stiff material elements because of the formation of creases in the gaps between them.