Scalable Multistep Roll-to-Roll Printing of Multifunctional and Robust Reentrant Microcavity Surfaces via a Wetting-Induced Process

Owing to their unique structural robustness, interconnected reentrant structures offer multifunctionality for various applications. a scalable multistep roll-to-roll printing method is proposed for fabricating reentrant microcavity surfaces, coined as wetting-induced interconnected reentrant geometry (WING) process. The key to the proposed WING process is a highly reproducible reentrant structure formation controlled by the capillary action during contact between prefabricated microcavity structure and spray-coated ultraviolet-curable resins. It demonstrates the superior liquid repellency of the WING structures, which maintain large contact angles even with low-surface-tension liquids, and their robust capability to retain solid particles and liquids under external forces. In addition, the scalable and continuous fabrication approach addresses the limitations of existing methods, providing a cost-effective and high-throughput solution for creating multifunctional reentrant surfaces for anti-icing, biofouling prevention, and particle capture.