Joey Mead

Industry-standard textile liquid repellency tests, including AATCC TM118 for non-polar oils and AATCC TM193 for polar water/isopropanol (IPA) mixtures, classified performance primarily according to liquid surface tension (γLV). In this study, we systematically compared the wetting of seven non-polar n-alkanes and seven polar water/IPA mixtures with matched surface tensions (21–32 mN/m) on a PFAS-free siloxane-based chemistry applied to both a smooth surface (glass) and a rough surface (woven nylon/cotton fabric). Contact angle measurements revealed that polar liquids consistently exhibited higher intrinsic contact angles than non-polar liquids with a comparable liquid surface tension γLV, demonstrating that liquid polarity plays a critical role beyond total surface tension alone. Surface energy analysis using Wu's harmonic-mean model attributed this divergence to the solid–liquid interfacial tension (γSL): non-polar liquids produced γSL values close to zero, whereas polar liquids exhibited substantially higher γSL values (approximately 6–18 mN/m). Hansen solubility parameter analysis further showed that the stronger affinity between non-polar oils and the siloxane-based surface promoted absorption and lowered interfacial resistance, providing a molecular explanation for their inferior repellency. On rough textile substrates, the non-polar liquids also exhibited enhanced wetting and a greater tendency to undergo Cassie-to-Wenzel transitions compared with polar liquids, despite having similar surface tensions. These findings demonstrate that liquid polarity and chemical affinity, rather than γLV alone, govern PFAS-free liquid repellency. We therefore propose that γSL and Hansen solubility distance (Ra) provide more physically meaningful descriptors for designing next-generation fluorine-free liquid-repellent textiles with improved resistance to low-surface-tension liquids.

The development of PFAS-free (per- and polyfluoroalkyl substances), liquid-repellent surfaces require a fundamental understanding of how surface geometry governs wetting-state stability. However, the independent role of interparticle spacing remains poorly understood because it is often coupled with changes in particle size, surface chemistry, or hierarchical morphology. Here, we present a geometry-driven strategy to systematically investigate the influence of spacing using re-entrant spherical architectures with controlled spacing ratios. Monodisperse 1 μm silica particles were immobilized within an epoxy matrix, while sacrificial 1 μm polystyrene spheres served as inert spacers to precisely tune interparticle distance without altering particle size or surface chemistry. After spacer removal and conformal hydrophobic silanization, wetting behavior was evaluated using ethanol–water mixtures with surface tensions ranging from 71.93 to 22.28 mN m–1. The apparent contact angle exhibits a nonmonotonic dependence on spacing ratio for liquids with surface tensions above approximately 25 mN m–1, reflecting a critical trade-off between reduced solid–liquid contact fraction, which enhances repellency, and diminished Cassie–Baxter state stability, which promotes wetting transition. As surface tension decreases, the optimal spacing ratio shifts toward smaller values, indicating increasingly stringent geometric requirements for sustaining the suspended wetting state. A theoretical framework integrating the Cassie–Baxter and Wenzel models with a breakthrough-pressure criterion quantitatively captures the experimental trends. These findings establish predictive design rules for geometry-controlled wetting and provide a scalable pathway for engineering high-performance, PFAS-free liquid-repellent coatings.

This study investigates the influence of PFAS-free superhydrophobic treatment on the performance of NYCO (50% Nylon 50% Cotton) fabric. The primary focus is to assess how these treatments influence key performance attributes, including water repellency, weight gain, air permeability, and color stability. The treatments were formulated using a silica/epoxy diluted with isopropanol (IPA), with the goal of achieving minimal weight gain (<10%) and high water repellency (AATCC22 rating of 80 or above) with a minimal impact on breathability and visual appearance. A series of formulations were prepared with a a constant silica to epoxy ratio (3:7) while varying the solids content of the suspension (1.8 to 5.2 wt.%). Treated fabrics were evaluated through water spray tests (AATCC TM 22), air permeability (ASTM D737), spectrophotometric color analysis, and SEM surface morphology. Samples treated with a formulation containing 2.0 wt.% solids content demonstrated the best performance characteristics: low weight gain, minimal breathability reduction, low color change, and water repellency. The findings reveal the potential for a PFAS-free treatment to achieve high water repellency while maintaining other key fabric performance characteristics. The results contribute to the advancement of sustainable, high-performance protective textiles for military applications.

A comprehensive study was conducted to develop structurally robust, crack-suppressed superhydrophilic nanocomposite coatings comprising poly(acrylic acid) (PAA) and silica nanoparticles. We systematically investigated the critical trade-off between particle loading, which drives surface wettability and stress-induced crack formation driven by capillary forces and shrinkage mismatch. Our findings identify a distinct structural failure threshold between 25 and 30 vol.% silica under conventional drying. By strategically optimizing drying kinetics (an initial flash-dry at 120 °C for 1 h followed by a 24 h ambient cure), we successfully fabricated transparent, crack-suppressed superhydrophilic coatings at elevated silica loadings up to 47 vol.%, establishing a practical, scalable framework for advanced functional surface engineering. The crack-suppressed mechanism was hypothesized to be related to internal stress.

While the effects of formulation variables of a rubber compound are well established for conventional rubber manufacturing techniques, their role in extrusion-based additive manufacturing remains underexplored. This study explores the impact of different base rubbers (NBR and EPDM) and curing agents (sulfur and peroxide) on processability and final part characteristics in material extrusion additive manufacturing applications. Under identical printing conditions, sulfur-cured NBR exhibits greater post-print shrinkage (12%) than sulfur-cured EPDM (7%). However, sulfur-cured NBR achieves a higher degree of adhesion between printed layers than sulfur-cured EPDM, as suggested by the % retention of the bulk materials’ ultimate stress by the printed parts (84–100% and 51–62%, respectively). Additionally, a peroxide-cured NBR formulation was compared against the same sulfur-cured NBR formulation. Printed parts from the peroxide-cured NBR formulation showed higher shrinkage (16%) and lower % retention of the bulk materials’ ultimate stress (26–33%) than the sulfur-cured NBR formulation. Additionally, the tensile behavior of all three rubber compounds was found to be strongly dependent on printing orientation, showing the anisotropic behavior typical of extrusion-based additive manufacturing. Sulfur-cured NBR showed the least anisotropy for stress at break (0.82) and strain at break (0.90), whereas peroxide-cured NBR showed the highest anisotropy in stress (0.74) and strain (0.82). The anisotropy ratios for sulfur-cured NBR and EPDM compounds were very similar for stress (0.82 vs. 0.82) and comparable for strain (0.90 vs. 0.87). Notably, the peroxide cure system provided almost twice as much available printing time as the sulfur cure system. This report on the effects of base rubber and curing agents on 3D printability and part properties provides a background to guide future efforts to design rubber compounds for 3D printing applications.

This work investigated the 3D printing of fully compounded thermoset elastomers using a custom-designed printer capable of processing both thermoplastics and elastomers containing fillers and specific cure packages. The adhesion strength between selected thermoset elastomers and thermoplastic combinations was studied, and the influence of key process parameters on adhesion was evaluated. The results showed that interfacial bonding was favored by the proximity of solubility parameters, the amorphous morphology of the thermoplastic, and increased chain mobility at the processing temperature. Rubber processing parameters significantly influenced adhesion, showing that curing at a lower temperature for a longer duration yielded better results than shorter, higher-temperature cures. Elemental analysis revealed the presence of rubber-specific components on the thermoplastic surface, suggesting interfacial migration. These findings contribute to advancing multi-material 3D printing by enabling the integration of rubber-like materials with thermoplastics, expanding opportunities for applications in high-temperature and chemically demanding environments.

Epoxy nanocomposites are widely used in various applications because of their excellent properties. Different types of manufacturing techniques are used to produce epoxy composites based on various fillers, molecular weight, and applications required. The physical properties and chemical structure of epoxy resin help in determining the method for its manufacturing. Coatings and adhesive formulations are prepared using high- molecular-weight epoxies, whereas epoxy nanocomposites require low-molecular-weight epoxies due to ease of manufacturing. A low-molecular-weight epoxy can provide high crosslink density to the epoxy but may also cause inherent brittleness in epoxy nanocomposites. Further, the addition of CNTs may also cause more brittleness in the final product. In this work, the authors have developed a method to process composites based on high-molecular-weight epoxy reinforced with high loading of CNTs (15 wt.%). The high molecular weight will bring lots of challenges during manufacturing. In this paper, a novel manufacturing technique based on separate molding and curing conditions to produce highly concentrated CNT-filled epoxy with high-molecular-weight epoxy resin is described, achieving excellent mechanical properties, good toughness, and high electrical conductivity in an efficient, low-cost, environmentally friendly, and high-volume way. The findings demonstrated improvements in these mechanical properties compared to conventional systems. They also highlight the potential of the novel method to develop advanced composite materials which can revolutionize industrial sectors such as aerospace, automotives, and electronics where structural integrity and thermal stability are important.

Superhydrophobic coatings are beneficial for applications like self-cleaning, anti-corrosion, and drag reduction. In this study, we investigated the impact of surface geometry on the static, dynamic, and sliding contact angles in the Cassie–Baxter state. We used fluoro-silane-treated silicon micro-post patterns fabricated via lithography as model surfaces. By varying the solid fraction (ϕ_s), edge-to-edge spacing (L), and the shape and arrangement of the micro-posts, we examined how these geometric factors influence wetting behavior. Our results show that the solid fraction is the key factor affecting both dynamic and sliding angles, while changes in shape and arrangement had minimal impact. The Cassie–Baxter model accurately predicted receding angles but struggled to predict advancing angles. These insights can guide the development of coatings with enhanced superhydrophobic properties, tailored to achieve higher contact angles and customized for different environmental conditions.

This work investigated material extrusion additive manufacturing (MatEx AM) of specialized fluoroelastomer (FKM) compounds for applications in rubber seals and gaskets. The influence of a commercially available perfluoropolyether (PFPE) plasticizer on the printability of a control FKM rubber compound was studied using a custom-designed ram material extruder, Additive Ram Material Extruder (ARME), for printing fully compounded thermoset elastomers. The plasticizer’s effectiveness was assessed based on its ability to address challenges such as high compound viscosity and post-print shrinkage, as well as its impact on interlayer adhesion. The addition of the PFPE plasticizer significantly reduced the FKM compound’s viscosity (by 70%) and post-print shrinkage (by 65%). While the addition of the plasticizer decreased the tensile strength of the control compound, specimens printed with the plasticized FKM retained 34% of the tensile strength of compression-molded samples, compared to only 23% for the unplasticized compound. Finally, the feasibility of seals and gaskets manufacturing using both conventional and unconventional additive manufacturing (AM) approaches was explored. A hybrid method combining AM and soft tooling for compression molding emerged as the optimal method for seal and gasket fabrication.

In this work, an additive manufacturing process for extruding fully compounded thermosetting elastomers based on fluorine-containing polymer compositions is reported. Additive manufacturing printers are designed with a dry ice container to precool filaments made from curable fluoroelastomer (FKM) and perfluoroelastomer (FFKM) compounds. A support tube guides the stiffened filament towards the printer nozzle. This support tube extends near the inlet to a printer nozzle. This approach allows low-modulus, uncured rubber filaments to be printed without buckling, a phenomenon common when 3D printing low-modulus elastomers via the fused deposition modeling (FDM) process. Modeling studies using thermal analyses data from a Dynamic Mechanical Analyzer (DMA) and a Differential Scanning Calorimeter (DSC) are used to calculate the Young’s modulus and buckling force, which helps us to select the appropriate applied pressure and the nozzle size for printing. Using this additive manufacturing (AM) method, the successful printing of FKM and FFKM compounds is demonstrated. This process can be used for the future manufacturing of seals or other parts from fluorine-containing polymers.