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This study investigates the micro-topographic surfaces as a benign anti-fouling/fouling-release method. The bio-inspired engineered surfaces were manufactured by controlling the viscoelastic instabilities of carbon nanotubes (CNTs) and polydimethylsiloxane (PDMS) nanocomposites using a customized, scalable two-roll coating process. The effects of manufacturing conditions, i.e., roller speed and roller radius-to-gap ratio, on surface properties, such as Wenzel roughness factor, peak density, water contact angle, and the tensile testing of the nanocomposite, were studied. The results showed that decreasing roller gap distance would significantly increase the hydrophobicity of the samples. Moreover, a positive correlation was observed between surface peak density and roughness factor. A textured sample was manufactured that significantly outperformed the non-textured CNT-PDMS, indicating a correlation between surface roughness and diatom attachment density. The dynamic diatom attachment assay showed up to 35% reduction in surface coverage of textured samples by the Navicula perminuta diatom compared to the non-textured CNT-PDMS control samples.

Micro-scale inorganic particles (d > 1 µm) have reduced surface area and higher density, making them negatively buoyant in most dip-coating mixtures. Their controlled delivery in hard-to-reach places through entrainment is possible but challenging due to the density mismatch between them and the liquid matrix called liquid carrier system (LCS). In this work, the particle transfer mechanism from the complex density mismatching mixture was investigated. The LCS solution was prepared and optimized using a polymer binder and an evaporating solvent. The inorganic particles were dispersed in the LCS by stirring at the just suspending speed to maintain the pseudo suspension characteristics for the heterogeneous mixture. The effect of solid loading and the binder volume fraction on solid transfer has been reported at room temperature. Two coating regimes are observed (i) heterogeneous coating where particle clusters are formed at a low capillary number and (ii) effective viscous regime, where full coverage can be observed on the substrate. 'Zero' particle entrainment was not observed even at a low capillary number of the mixture, which can be attributed to the presence of the binder and hydrodynamic flow of the particles due to the stirring of the mixture. The critical film thickness for particle entrainment is [Formula: see text] for 6.5% binder and [Formula: see text] for 10.5% binder, which are smaller than previously reported in literature. Furthermore, the transferred particle matrices closely follow the analytical expression (modified LLD) of density matching suspension which demonstrate that the density mismatch effect can be neutralized with the stirring energy. The findings of this research will help to understand this high-volume solid transfer technique and develop novel manufacturing processes., (© 2022. The Author(s).)