Rational design of static wetting on roughness-engineered heterogeneous surfaces

Surface roughness and chemical composition are crucial in controlling the static wetting properties of surfaces. Here, conventional surface structuring methods used in Si microfabrication are used as a reference to analyze the impact of precisely engineered surface roughness. The static wettability of rough chemically heterogeneous surfaces is experimentally studied through contact angle measurements and compared against computational simulations to categorize the wetting behavior of water droplets. Heterogeneous samples are observed to already show significant dependence on the surface fraction covered by each material. Furthermore, owing to the presence of a resist layer on top of the Si pillars, intermediate states between the Wenzel (W) and Cassie–Baxter (CB) models are observed. Consistent with these models, we find that local chemical modifications of microstructured surfaces are crucial for controlling their surface wettability properties. Additionally, a comparison of equivalent microstructures made of Si or polydimethylsiloxane (PDMS) reveals the quantitative impact of the hydrophilic/hydrophobic nature of the material on the evolution of the wetting properties with increasing roughness factors. While Si surfaces behave according to the W model, PDMS surfaces show intermediate wetting states at significantly lower roughness levels. Bubbles trapped beneath water droplets demonstrate the existence of intermediate states that cannot be defined by either the W or CB models. By combining experimental results with finite element simulations, we not only demonstrate wettability control through specific roughness and chemical modifications but also provide insight into how these parameters interact to accurately predict and adjust static wetting properties.