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3D Printing of Objects with Bulk Superhydrophobicity Using Self-Foaming Polydimethylsiloxane-Based Ink
Ruifeng Jiang1, Xiao Wang1, Shengmao Chao1
1Chengdu Development Center of Science and Technology, China Academy of Engineering Physics, Chengdu 610200, China.
ACS Applied Materials & Interfaces
|April 30, 2025
Summary
A new solvent-free ink enables 3D printing of durable, superhydrophobic objects using polydimethylsiloxane (PDMS). This environmentally friendly method creates lightweight, robust materials for waterproofing and oil-water separation applications.
Area of Science:
- Materials Science
- Surface Chemistry
- Additive Manufacturing
Background:
- Durable superhydrophobic materials are crucial for various applications, but their fabrication via 3D printing is hindered by solvent use and complex processes.
- Existing methods often struggle with maintaining superhydrophobicity in bulk structures and require intricate manufacturing steps.
Purpose of the Study:
- To develop a solvent-free, self-foaming ink for 3D printing bulk superhydrophobic objects.
- To achieve robust, hierarchical surface structures and low surface energy for enhanced water repellency.
- To demonstrate the material's durability and versatile applications through 3D printing.
Main Methods:
- Formulation of a polydimethylsiloxane (PDMS)-based ink with thermally expandable microspheres (EMs) and polytetrafluoroethylene (PTFE) particles.
- 3D printing of bulk superhydrophobic objects using the developed ink.
- Characterization of surface morphology, superhydrophobicity (water contact angle, sliding angle), and material durability (abrasion cycles).
- Evaluation of the printed foam's density and performance in waterproofing, oil-water separation, and buoyancy applications.
Main Results:
- A solvent-free, self-foaming PDMS ink was successfully developed for 3D printing.
- The printed material achieved Cassie-state superhydrophobicity (water contact angle of 155°, sliding angle of 9°) due to hierarchical roughness and low surface energy.
- The superhydrophobic foam demonstrated exceptional durability, retaining properties after 1000 abrasion cycles.
- The lightweight foam (0.16 g/cm³) showed potential in waterproofing, oil-water separation, and as a drone buoyancy carrier.
Conclusions:
- This work presents a facile and environmentally benign strategy for fabricating robust, bulk superhydrophobic materials via scalable 3D printing.
- The developed PDMS-based ink and printing method overcome limitations of traditional approaches, enabling practical applications.
- The material's durability and performance highlight its potential for sustainable industrial and environmental solutions.
