3D printing and rapid replication of advanced numerically generated rough surface topographies in numerous polymers

Perris, J., Kumar, C. , Xu, Y. , Tassieri, M. , Kartal, M. E., Gadegaard, N. and Mulvihill, D. M. (2023) 3D printing and rapid replication of advanced numerically generated rough surface topographies in numerous polymers. Advanced Engineering Materials, 25(1), 2200832. (doi: 10.1002/adem.202200832)

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An approach to rapidly produce high quality polymer surface topographies from numerically generated surfaces is presented. The approach uses an advanced surface generation tool to flexibly design surfaces with user defined topography characteristics over a large range of surface roughness. Roughness instances with RMS roughness 25, 50, and 100 μm are studied. 3D printing is used to create a master surface and polymer casting and injection moulding are employed to enable rapid replication in various polymers. The cross-correlation ratio (CCR) and a mean difference approach were used to assess replication quality. Injection moulding provides high-throughput with high replication quality up to CCR ≈ 0.74. While casting in low-viscosity polymer resins enables slightly improved high-quality replication (CCR up to ∽0.82) with reduced through-put. Key results include the ability of the 3D printed surfaces to replicate tailored variations in surface topography (e.g. amplitude and frequency) and the importance of low viscosity resins in maximising replication quality in polymer casting. Several interfacial and surface phenomena (both mechanical and biological) are sensitive to surface roughness. The main application lies in providing a valuable tool for research looking at topography influencing phenomena ranging from friction and lubrication to aerodynamic drag, algae growth and cell growth.

Item Type:Articles
Glasgow Author(s) Enlighten ID:Xu, Dr Yang and Tassieri, Dr Manlio and Perris, Jack and Mulvihill, Dr Daniel and Kumar, Dr Charchit and Gadegaard, Professor Nikolaj
Authors: Perris, J., Kumar, C., Xu, Y., Tassieri, M., Kartal, M. E., Gadegaard, N., and Mulvihill, D. M.
College/School:College of Science and Engineering > School of Engineering > Biomedical Engineering
College of Science and Engineering > School of Engineering > Systems Power and Energy
Journal Name:Advanced Engineering Materials
ISSN (Online):1527-2648
Published Online:12 August 2022
Copyright Holders:Copyright © 2022 The Authors
First Published:First published in Advanced Engineering Materials 25(1): 2200832
Publisher Policy:Reproduced under a Creative Commons License

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Project CodeAward NoProject NamePrincipal InvestigatorFunder's NameFunder RefLead Dept
302858Fundamental Mechanical Behaviour of Nano and Micro Structured InterfacesDaniel MulvihillLeverhulme Trust (LEVERHUL)RPG-2017-353ENG - Systems Power & Energy
172025FAKIR: Focal Adhesion Kinetics In nanosurface RecognitionNikolaj GadegaardEuropean Research Council (ERC)648892ENG - Biomedical Engineering