Evaluating the effect of processing parameters on the replication quality in the micro compression molding of silicone rubber

Given the role of micro-nanostructures in producing superhydrophobic and icephobic surfaces and the importance of high-quality replication of these micro-nanostructures in direct replication processes, we evaluated the effect of processing parameters on the superhydrophobicity, icephobicity, and replication quality of silicone rubber surfaces created via micro-compression molding. Molding pressure, mold temperature, curing time, and part thickness were selected as the processing parameters to be assessed. We used a response surface methodology to illustrate the optimal values of the selected processing parameters. Molding pressure and part thickness were the main influencing parameters to attain the superhydrophobicity. In a second set of experiments, we assessed the replication quality of silicone rubber surfaces of variable thickness subjected to different molding pressures. Each part thickness had an optimal molding pressure for obtaining the best replication quality. Surfaces having the highest replication quality also demonstrated the longest freezing delay and confirmed their potential use as anti-icing surfaces. Although all developed superhydrophobic surfaces showed icephobicity, the influence of processing parameters affecting ice adhesion was complex.