Bioinspired electrohydrodynamic ceramic patterning of curved metallic substrates

Template-assisted electrohydrodynamic atomisation (TAEA) has been used for the first time to pattern curved metallic surfaces. Parallel lines of ceramic titania (TiO 2 ) were produced on titanium substrates, convex and concave with diameters of ~25 mm, at the ambient temperature. Optimal results were obtained with 4 wt% TiO 2 in ethanol suspension deposited over 300 s during stable cone-jetting at 20 µl/min, 10kV and collection distance 80 mm. A high degree of control over pattern line width, interline spacing and thickness were achieved. Nanoindentation load-displacement curves were continuous for the full loading and unloading cycle, indicating good adhesion between pattern and substrate. At a loading rate of 1 μN/s and a hold time of 1 s, pattern hardness decreased as load increased up to 7 μN and remained at 0·1 GPa up to higher loads. Elastic modulus behaved similarly, and both were not sensitive to loading rate. The effect of heat treatment to further consolidate the patterned deposits was also investigated. Hardness of the patterns was not markedly affected by heating. This work shows that TAEA is highly controllable and compatible on a range of substrate geometries. Extending TAEA capabilities from flat to curved surfaces, enabling the bioactive patterning of different surface geometries, takes this technology closer to orthopaedic engineering applications.