Superhydrophobic surfaces, characterized by exceptional water repellency and self-cleaning properties, have gained significant attention for their diverse applications across industries. This review paper comprehensively explores the theoretical foundations, various fabrication methods, applications, and associated challenges of superhydrophobic surfaces. The theoretical section investigates the underlying principles, focusing on models such as Young’s equation, Wenzel and Cassie–Baxter states, and the dynamics of wetting. Various fabrication methods are explored, ranging from microstructuring and nanostructuring techniques to advanced material coatings, shedding light on the evolution of surface engineering. The extensive applications of superhydrophobic surfaces, spanning from self-cleaning technologies to oil–water separation, are systematically discussed, emphasizing their potential contributions to diverse fields such as healthcare, energy, and environmental protection. Despite their promising attributes, superhydrophobic surfaces also face significant challenges, including durability and scalability issues, environmental concerns, and limitations in achieving multifunctionality, which are discussed in this paper. By providing a comprehensive overview of the current state of superhydrophobic research, this review aims to guide future investigations and inspire innovations in the development and utilization of these fascinating surfaces.

Aluminum (Al) is widely used in all forms of industry, including automobile, aerospace, transmission lines, and exchangers, and in general household appliances. Ice accumulation on Al surfaces may cause serious problems, especially during the winter, leading to critical damage to mechanical systems. In this study, we developed a superhydrophobic coating with anti-icing properties on an Al surface using a simple and cost-effective technique. The superhydrophobic dual-shape micro-/nanostructured (MN-) Al surface was fabricated by a facile chemical etching and an anodization method, followed by surface modification with polydimethylsiloxane (PDMS) via a simple thermal vapor deposition method. The static contact angle of the fabricated surface was more than 160 °C. Compared with the bare surface and the silicone oil-infused PDMS coating (SLIPS) on the MN-structured Al substrate, the fabricated superhydrophobic surface displayed excellent anti-icing. Ice formation on the superhydrophobic surface was delayed by 80 and 45 min at −5 °C and −10 °C, respectively, at a relative humidity of 80% ± 5%. The superhydrophobic surface demonstrated an increase of almost four and two times delay in icing time on the surface over bare and SLIPS surfaces, respectively. The coalescence induced jumping behavior of condensate water droplets was also investigated on the fabricated surfaces. The result indicates that the superhydrophobic surface can effectively delay ice/frost formation by the synergetic effect of surface morphology and the extremely low adhesive property of the surfaces, which allows the self-propelled jumping phenomenon at low temperature and high humidity. This proposed simple, fast, and cost-effective method could be applied to design large-scale anti-icing surfaces.