Application of Pulsed Electro Chemical Machining (PECM) process to replicate micro textures and functionalize surfaces

Pulsed ElectroChemical Machining (PECM) is investigated as a high-precision method for replicating hydrophobic microstructures on stainless-steel knife blades to reduce meat adhesion and lower industrial water consumption. Surface functionalization inspired by biomimetic models, particularly lotus-leaf-type textures, requires controlled micro and nano-scale geometries to modify wettability and reduce surface energy. In this study, a femtosecond laser is used to fabricate a highly dense hexagonal micro-texture on a 316L stainless-steel cathode, consisting of 165 µm cavities with 50 µm depth. This electrode is used for PECM replication onto X46Cr13 blades. PECM, a non-contact and non-thermal anodic dissolution process, allows precise reproduction of complex patterns due to a very small space between the electrode and the workpiece and the synchronized pulsed currents. Texturing is achieved in less than one minute, independently of surface area, demonstrating strong scalability. Wettability measurements show an 11% rise in water contact angle and a corresponding decrease in surface energy, indicating a transition from hydrophilic to hydrophobic surface. Adhesion tests with pork meat show that the developed texture allows for effective reduction of meat adhesion, with the adhered mass being reduced by up to 40% before washing and 60% after washing.