Review of preparation methods for micro–nano structured superhydrophobic surfaces: formation mechanisms, performance simulation, and process analysis

Superhydrophobic surfaces (SHSs), characterized by unique wettability and low surface energy, have attracted considerable attention for their potential application in self-cleaning, corrosion protection, anti-icing, and drag reduction. These functions can be achieved through numerous preparation methods and can be adapted to different application scenarios and its' specific requirements. To achieve good performance on SHSs, it is often necessary to combine the design theory and performance simulation methods, which can reduce the cost of trial and error. This paper introduces the relevant research progress in superhydrophobic theory and numerical simulation; the preparation methods of superhydrophobic surfaces are reviewed in detail, including the template method, etching method, deposition method, sol-gel method, and 3D printing method. By systematically teasing out the principles and characteristics of each method and conducting comparative analyses, the pros and cons of each method can be identified. This can provide technical references for the preparation of SHSs with different functions. Finally, this review provides the conclusion about the challenges of SHSs to outline the future research prospect. Future research on superhydrophobic surfaces will focus on improving the comprehensive performance, reducing costs, integrating multi-functions, and advancing environmental protection to boost their durability, industrial applicability, functional synergies, and environmental friendliness.