A novel conformal coating process is presented to transform surfaces with micro-morphology into hierarchical superhydrophobic surfaces using one-step, wet chemical spray casting. The nanocomposite coating consists of zinc oxide nanoparticles and organomodified polydimethylsiloxane (PDMS), also known as organosilane quaternary nitrogen compound. The coating is applied to a micro-patterned PDMS substrate of cylindrical microposts to create a stable superhydrophobic state for water droplets. An explanation for the non-wetting performance of the conformal nanocomposite coatings compared to previous non-conformal surfaces is also proposed.

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