Impact of Replicated Biomimetic Microstructures on the Wettability of Injection-Molded Polymer Surfaces

This article evaluates the influence of replicated natural structures, produced by micro-machining, on the wettability of plastic parts made from hydrophilic and hydrophobic polymer materials under various temperature and pressure conditions. Although many studies have focused on biomimetic surface design, the effect of specific processing parameters on the accurate replication of natural topologies and their resulting wettability has been only partially explored. This study addresses this gap by systematically analyzing the effect of melt temperature and packing pressure on the functional replication of micro-machined biomimetic structures. The research describes the design of hierarchical microstructures inspired by biomimetics and their fabrication by micro-milling on molded parts. Test samples were prepared from polypropylene (PP), acrylonitrile butadiene styrene (ABS), and polyamide 6.6 (PA 6.6) under different processing parameters, and wettability was assessed using contact angle (CA) measurements. The results confirmed significant variations in surface wettability depending on polymer type, melt temperature, and packing pressure. For the hydrophilic relief (Rock Moss), contact angles below 90° were obtained for all tested polymers, including PP, which decreased from 98.7° on a flat surface to 82.4° at 220 °C and 500 bar. In PA 6.6, a reduction of up to 12% in contact angle was observed compared to smooth samples at 310 °C and 500 bar. For hydrophobic reliefs (Three-part Hibiscus and Tricolor Pansy), contact angles exceeded 100-110°, with the highest value of 108.3 ± 1.6° for PP at 200 °C and 500 bar. Suitable combinations of melt temperature and packing pressure enabled accurate replication of microstructures while preserving their functional wettability, demonstrating the possibility of tuning surface properties through topological design.