Thermally Driven Wrinkle Realignment for Morphology-Controlled Enhancement of Dry Adhesion Performance

In this study, we developed a novel and scalable strategy for fabricating aligned wrinkle patterns through thermal expansion and contraction. Carbon nanotubes were incorporated into polydimethylsiloxane to enhance its (i.e., PDMS) heat transfer within the bilayer structure. This thermal activation enabled reversible wrinkle arrangement, allowing for the formation of highly ordered wrinkle morphologies through a purely physical process, without the need for vacuum conditions or complex precursor synthesis. The influences of geometric parameters (the sample aspect ratio and size) on wrinkle alignment were systematically investigated. We identified that the synergistic coexistence of flat regions and aligned wrinkle patterns enhances dry adhesion. The flat region increases the real contact area, whereas the wrinkled region provides mechanical interlocking and suppresses crack propagation. This study found that surface roughness, wrinkle morphology, and spatial wrinkle arrangement play critical roles in determining dry adhesion performance. In summary, this paper presents a facile, reversible, and industrially viable approach for generating functional surface patterns that can be employed in a wide range of emerging technologies.