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Updated: May 21, 2025

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Enabling Soft Molds for Manufacturing Polymeric Surface Structures with Overhangs.

Qingyang Sun1, Tingyi Leo Liu1,2

  • 1Department of Mechanical and Industrial Engineering, University of Massachusetts Amherst, Amherst 01003, Massachusetts, United States.

Langmuir : the ACS Journal of Surfaces and Colloids
|May 7, 2025
PubMed
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This study developed a model for soft mold design to overcome manufacturing challenges with overhanging surface structures. The validated model enables high-fidelity replication of complex biomimetic surfaces for advanced applications.

Area of Science:

  • Materials Science
  • Biomimetics
  • Manufacturing Engineering

Background:

  • Surface structures with overhangs are common in nature but difficult to manufacture due to mold interlock.
  • Existing soft molds face challenges with stiction and collapsing at the microscale.

Purpose of the Study:

  • To model the relationship between overhang geometry and material properties for robust soft mold design.
  • To enable high-fidelity manufacturing of complex biomimetic surfaces with hierarchical overhangs.

Main Methods:

  • Developed a predictive model for soft mold design considering flexibility and structural integrity.
  • Verified the model using polydimethylsiloxane (PDMS) molds with varying properties and geometries.
  • Molded doubly re-entrant surface structures using validated soft molds and thermosetting polymers.

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Main Results:

  • The model demonstrated excellent agreement with experimental data from PDMS and literature soft molds.
  • Successfully replicated complex hierarchical overhang structures with high fidelity.
  • Achieved surfaces that repel low-energy fluids without requiring coatings.

Conclusions:

  • Established key design principles for soft mold fabrication to prevent interlock and enable complex overhang formation.
  • The findings pave the way for large-scale manufacturing of intricate biomimetic surfaces.
  • Demonstrated the potential for creating advanced functional surfaces for various applications.