Researchers at the Georgia Institute of Technology have developed a method of making gecko-inspired adhesive materials that is cost-effective than current methods, enabling mass production and spread of versatile gripping strips.
Gecko-inspired Adhesives – An Advantage to Manufacturers
“With the exception of things like Teflon, it will adhere to anything. This is a clear advantage in manufacturing because we don’t have to prepare the gripper for specific surfaces we want to lift. Gecko-inspired adhesives can lift flat objects like boxes then turn around and lift curved objects like eggs and vegetables,” said Michael Varenberg, the study’s principal investigator and an assistant professor in Georgia Tech’s George W. Woodruff School of Mechanical Engineering.
Current grippers on assembly lines, such as clamps, magnets, and suction cups, can each lift limited ranges of objects. Grippers based on gecko-inspired surfaces, which are dry and contain no glue can replace many grippers or fill capability gaps left by other gripping mechanisms.
Forming Mesoscale Walls with New Method
The adhesion comes from protrusions a few hundred microns in size that often look like sections of short, floppy walls running parallel to each other across the material’s surface. Earlier molding, an inconvenient technique, was used to form mesoscale walls.
In the new method the researchers formed mesoscale walls by pouring ingredients onto a smooth surface instead of a mold, letting the polymer partially set then dipping rows of laboratory razor blades into it. The material set a little more around the blades, which were then drawn out, leaving behind micron-scale indentations surrounded by the desired walls.
New Adhesive can be Used in Industries and Homes
“There are many parameters to control: Viscosity and temperature of the liquid; timing, speed, and distance of withdrawing the blades. We needed enough plasticity of the setting polymer to the blades to stretch the walls up, and not so much rigidity that would lead the walls to rip up,” added Varenberg.
Gecko-inspired surfaces have a fine topography on a micron-scale and sometimes even on a nanoscale, and surfaces made via molding are usually the most precise. But such perfection is unnecessary; the materials made with the new method did the job well and were also markedly robust.
“Many researchers demonstrating gecko adhesion have to do it in a cleanroom in clean gear. Our system just plain works in normal settings. It is robust and simple, and I think it has good potential for use in industry and homes,” said Varenberg, who studies surfaces in nature to mimic their advantageous qualities in human-made materials.
Ridges in Gecko Foot Creates Adhesion
Electron microscopes of Gecko foot reveal a spatula-shaped bristly fibril protrude a few dozen microns long off those ridges. The fibrils make such thorough contact with surfaces down to the nanoscale that weak attractions between atoms on both sides appear to add up enormously to create overall strong adhesion.
In place of fluff, engineers have developed rows of shapes covering materials that produce the effect. A common shape makes a material’s surface look like a field of mushrooms that are a few hundred microns in size; another is rows of short walls like those in this study.
“The mushroom patterns touch a surface, and they are attached straightaway, but detaching requires applying forces that can be disadvantageous. The wall-shaped projections require minor shear force like a tug or a gentle grab to generate adherence, but that is easy, and letting go of the object is uncomplicated, too,” said Varenberg.
Varenberg’s research team used the drawing method to make walls with U-shaped spaces in between them and walls with V-shaped spaces in between. They worked with polyvinylsiloxane (PVS) and polyurethane (PU). The V-shape made in PVS worked best, but polyurethane is the better material for industry, so Vanenberg’s group will now work toward achieving the V-shape gecko gripping pattern in PU for the best possible combination.
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