Wet chemistry methods such as sol-gel provide a facile means of preparing coatings with controlled surface chemistry and architecture. The manipulation of colloidal "building blocks," film constituents, and reaction conditions makes it a promising method for simple, scalable, and routine production of superhydrophobic coatings. Despite all of this, the practical application of superhydrophobic coatings remains limited by low mechanical durability. The translation of chemistry to mechanical strength within superhydrophobic films is severely hindered by the requisite physical structure. More specifically, porosity and the surface architecture of roughness in sol-gel-derived films contribute significantly to poor mechanical properties. These physical effects emphasize that collective structure and chemistry-based strategies are required. This challenge is not unique to superhydrophobics, and there are many principles that can be drawn upon to greatly improve performance. The delicate interplay between chemistry and physical structure has been highlighted through theory and characterization of porous and rough interfaces within and outside the framework of superhydrophobics. Insights can further be drawn from biology. Nature's capacity for self-repair remains extremely challenging to mimic in materials. However, nature does demonstrate strategies for structuring nano- and microbuilding blocks to achieve generally mutually exclusive properties. Difficulties with characterization and example mechanical characterization methods have also been emphasized.
Keywords: biomimetic; crater; durable; needle; review; sol−gel; structure; superhydrophobic.