Preparation and Application of Functional Material Surfaces based on 3D-printed Microstructures

Abstract

With the rapid development of micro- and nano-manufacturing technologies, 3D printing, owing to its high design flexibility and excellent forming capabilities, has provided a promising approach for constructing material surfaces with specific functions. This paper aims to review the preparation processes for functional material surfaces based on 3D-printed microstructures and their applications across multiple fields. First, mainstream 3D printing technologies for functional surface fabrication, such as photopolymerization, material extrusion, and powder bed fusion, are introduced, along with an explanation of their processing mechanisms and the advantages and inherent limitations in microstructure formation. Subsequently, the paper focuses on how precise control can be used to replicate and innovate biomimetic microstructures. By constructing specific microcolumn arrays, groove networks, or multi-level composite structures, it is possible to effectively alter the functional properties of material surfaces, such as hydrophobicity and anti-icing capabilities. Building on this, the paper summarizes the application progress of such microstructured functional surfaces in emerging fields, including self-cleaning and anti-fouling coatings, highly efficient heat transfer enhancement, drag and noise reduction, and flexible electronic devices. Finally, a critical analysis is conducted regarding the challenges currently faced by 3D printing in cross-scale manufacturing, structural durability, and mass production. Future directions are clarified through specific scientific questions and technical pathways, avoiding vague generalizations. This review systematically summarizes the current understanding that microstructural morphology governs macroscopic functional properties, such as superhydrophobicity, anti-icing, drag reduction, and corrosion resistance, by regulating surface energy, stress distribution, heat transfer, and charge distribution, thereby providing a theoretical basis for targeted design.