Scalable Fabrication of Biomimetic Antibacterial Nanospikes on PMMA Films Using Atmospheric-Pressure Low-Temperature Plasma

Antibacterial surfaces inspired by biological micro- and nanostructures, such as those found on the wings of cicadas and dragonflies, have attracted interest due to their ability to inhibit bacterial adhesion and damage microbial membranes without relying on chemical agents. However, conventional fabrication techniques like photolithography or nanoimprinting are limited by substrate shape, size, and high operational costs. In this study, we developed a scalable method using atmospheric-pressure low-temperature plasma (APLTP) to fabricate sharp-edged nanospikes on solvent-cast polymethyl methacrylate (PMMA) films. The nanospikes were formed through plasma-induced modification of pores in the film, followed by annealing to control surface wettability while maintaining structural sharpness. Atomic force microscopy confirmed the formation of micro/nanostructures, and contact angle measurements revealed reversible hydrophilicity. Antibacterial performance was evaluated against <i>Escherichia coli</i> using ISO 22196 standards. While the film with only plasma treatment reduced bacterial colonies by 30%, the film annealed after plasma treatment achieved an antibacterial activity value greater than 5, with bacterial counts below the detection limit (<10 CFU). These findings demonstrate that APLTP offers a practical route for large-area fabrication of biomimetic antibacterial coatings on flexible polymer substrates, holding promise for future applications in healthcare, packaging, and public hygiene.