Manufacturing of Bionic Adhesion Microstructure with Expanded Ends Based on Electroplating in the Restricted Area.

Area of Science:

• Biomimetics and Materials Science
• Microfabrication Technologies
• Adhesion Science

Background:

• Animals with advanced locomotion exhibit complex 3D structures enabling substrate adhesion.
• Bionic adhesion technology relies on designing and manufacturing complex microstructures for effective adhesion.
• End-expanded microstructures offer high adhesion under low preload, crucial for handling delicate items.

Purpose of the Study:

• To propose a microfabrication technology for nickel molds used in bionic adhesion.
• To investigate the impact of electric field inhomogeneity on electrodeposition.
• To fabricate and characterize bionic adhesives with end-expanded microstructures.

Main Methods:

• Utilized three-dimensional (3D) printing for initial mold design.
• Employed electroplating to create nickel molds with high mechanical strength.
• Applied roll-to-roll hot embossing (R2R-HE) to produce bionic adhesives.
• Systematically studied electric field effects on electrodeposition morphology.

Main Results:

• Successfully fabricated nickel molds using 3D printing and electroplating.
• Achieved typical bionic adhesives with end-expanded microstructures via R2R-HE.
• Demonstrated a normal adhesion force of 9.5 N/cm², comparable to gecko adhesion.
• Established a link between electric field inhomogeneity and electrodeposition outcomes.

Conclusions:

• A novel microfabrication approach combining 3D printing and electroplating is effective for complex bionic mold creation.
• The developed method enables the production of high-performance bionic adhesives.
• This technology offers a new pathway for large-area bionic adhesion structures and nondestructive handling applications.