Scalable production of double-layer superhydrophobic coating with superior adhesion and high corrosion resistance via screen printing and UV curing

This study addresses the challenges of mass production and extensive application of superhydrophobic coatings, focusing on adhesion and durability. We propose an innovative solution utilizing screen printing and UV curing techniques, offering a simple, replicable, and scalable process. Our two-step strategy involves applying a polyurethane diacrylate (PUA-2) adhesion layer to the glass surface through screen printing and UV curing to ensure superior adhesion. Next, a polyurethane hexaacrylate (PUA-6) based formulation is applied over the adhesion layer and subjected to light curing, resulting in excellent hydrophobicity, scratch resistance, and corrosion resistance. This method withstands a pullout force exceeding 5 MPa, achieving a water contact angle of 164.3° and a sliding angle of 1.6°. The coating maintains favorable superhydrophobicity after 80 rounds of sandpaper friction and demonstrates promising corrosion resistance in a 3.5 % NaCl solution. Notably, this approach streamlines large-scale production and delivers exceptional, well-defined performance, providing a promising avenue for widespread and sustainable applications of superhydrophobic coatings.