Scalable Manufacturing of Bending-Induced Surface Wrinkles

The wide range of textures that can be generated via wrinkling can imbue surfaces with functionalities useful for a variety of applications including tunable optics, stretchable electronics, and coatings with controlled wettability and adhesion. Conventional methods of wrinkle fabrication rely on batch processes in piece-by-piece fashion, not amenable for scale-up to enable commercialization of surface wrinkle-related technologies. In this work, a scalable manufacturing method for surface wrinkles is demonstrated on a cylindrical support using bending-induced strains. A bending strain is introduced to a thin layer of ultraviolet-curable poly(dimethylsiloxane) (UV-PDMS) coated on top of a soft PDMS substrate by wrapping the bilayer around a cylindrical roller. After curing the UV-PDMS and subsequently releasing the bending strain, one-dimensional or checkerboard surface wrinkles are produced. Based on experimental and computational analyses, we show that these patterns form as a result of the interplay between swelling and bending strains. The feasibility of continuous manufacturing of surface wrinkles is demonstrated by using a two-roller roll-to-roll prototype, which paves the way for scalable roll-to-roll processing. To demonstrate the utility of these textures, we show that surface wrinkles produced in this manner enhance the light harvesting and thus efficiency of a solar cell at oblique angles of illumination due to their strong light scattering properties.