The superlative adhesive properties of some biological attachment systems, such as those of geckos, spiders, and insects, have inspired researchers from different fields (e.g. biology, physics and engineering) to conceive and design man-made microstructured surfaces that might mimic their performance. Among the several proposed designs, very recently mushroom-shaped adhesive microstructures have drawn the interest of scientists and engineers, because experiments have proved their superiority compared to other micro- and nano-structures. In this article, we explain theoretically the physical mechanism behind the enhanced adhesion of such microstructures, and provide for the first time a useful tool to predict adhesive performance depending on the geometry, mechanical properties of the material, and energy of adhesion. Our theoretical predictions are strongly supported by the available experimental data. The present study can streamline the optimisation of adhesive microstructures for industrial applications.

We investigate the loading and unloading behavior of soft solids in adhesive contact with randomly rough profiles. The roughness is assumed to be described by a self-affine fractal on a limited range of wave vectors. A spectral method is exploited to generate such randomly rough surfaces. The results are statistically averaged, and the calculated contact area and applied load are shown as a function of the penetration, for loading and unloading conditions. We found that the combination of adhesion forces and roughness leads to a hysteresis loading-unloading loop. This shows that energy can be lost simply as a consequence of roughness and van der Waals forces, as in this case a large number of local energy minima exist and the system may be trapped in metastable states. We numerically quantify the hysteretic loss and assess the influence of the surface statistical properties and the energy of adhesion on the hysteresis process.

We studied experimentally and theoretically the effect of different tilt angles on the adhesion of mushroom-shaped adhesive microstructures. The marginal measured influence of tilting on pull-off forces is quantitatively well confirmed by numerical and theoretical calculations and was shown to be a direct consequence of an optimized stress distribution. In addition, the presence of a joint-like narrowing under the contact elements, as found in some biological attachment systems, was shown to further contribute to the tilt-tolerance. The results obtained allow us to explain the advantage of the widely observed mushroom-shaped contact geometry in nature for long-term and permanent adhesion.