Synthetic dry adhesives inspired by the nano-and micro-scale hairs found on the feet of geckos and some spiders have beendeveloped for almost a decade. Elastomeric single level micro-scale mushroom shaped fibres are currently able to function evenbetter than natural dry adhesives on smooth surfaces under normal loading. However, the adhesion of these single level syntheticdry adhesives on rough surfaces is still not optimal because of the reduced contact surface area. In nature, contact area ismaximized by hierarchically structuring different scales of fibres capable of conforming surface roughness. In this paper, weadapt the nature’s solution arid propose a novel dual-level hierarchical adhesive design using Polydimethylsiloxane (PDMS),which is tested under peel loading at different orientations. A negative macro-scale mold is manufactured by using a laser cutterto define holes in a Poly(methyl methacrylate) (PMMA) plate. After casting PDMS macro-scale fibres by using the obtainedPMMA mold, a previously prepared micro-fibre adhesive is bonded to the macro-scale fibre substrate. Once the bondingpolymer is cured, the micro-fibre adhesive is cut to form macro scale mushroom caps. Each macro-fibre of the resulting hierarchicaladhesive is able to conform to loads applied in different directions. The dual-level structure enhances the peel strengthon smooth surfaces compared to a single-level dry adhesive, but also weakens the shear strength of the adhesive for a given areain contact. The adhesive appears to be very performance sensitive to the specific size of the fibre tips, and experiments indicatethat designing hierarchical structures is not as simple as placing multiple scales of fibres on top of one another, but can requiresignificant design optimization to enhance the contact mechanics and adhesion strength.
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