Replication of polyethylene nano-micro hierarchical structures using ultrasonic forming

We present the replication of polyethylene (PE) nano-micro hierarchical structures and their application for superhydrophobic surfaces. A commercial ultrasonic welding system was used to apply ultrasonic vibration energy to the forming of nano-micro hierarchical structures. To evaluate ultrasonic formability, Ni nanomold and nano-micro hierarchical mold were designed and fabricated. The optimal weld times were 1.5 s and 3.0 s for PE nanoprotrusions and nano-micro hierarchical structures, respectively. The forming process was conducted at atmospheric pressure. The PE structures were well replicated without a vacuum. The trapped air in the microcavity of the nano-micromold was dispersed and absorbed into the molten PE. Ultrasonic nano-microreplication technology showed an extremely short processing time and did not require a vacuum environment. To investigate the applicability of ultrasonic forming, the fabricated nanoprotrusions and nano-micro hierarchical structures were coated with plasma polymerized fluorocarbon (PPFC) of a hydrophobic nature and were applied to modify superhydrophobic surfaces. The contact angle was increased from 106° (smooth surface) to 125° (nanostructured surface) and finally to 160° (nano-microstructured surface) so that the surface became superhydrophobic.