Mesh‐Armored Re‐Entrant Structures via Solvent Evaporation‐Induced Fragmentation for Abrasion‐Durable Super‐Repellent Surfaces

Abstract Super‐repellent surfaces hold significant potential in engineering applications such as self‐cleaning, antifouling, and drag reduction. However, their practical implementation has been hindered by challenges in scalable fabrication and mechanical fragility. This study presents an innovative and scalable strategy to fabricate hierarchical micro‐nano re‐entrant structures using a stainless‐steel mesh framework. By dip‐coating the mesh in a nanoparticle‐incorporated superhydrophobic coating, it is observed that the superhydrophobic mesh re‐entrant (SHM‐R) structures spontaneously form within mesh pores through solvent evaporation‐induced membrane fragmentation. The SHM‐R surface exhibits exceptional super‐repellency, with a water apparent contact angle of 160.3 ± 1.6° (sliding angle 0.9 ± 0.3°) and a 30% ethanol apparent contact angle of 150.6 ± 4.6° (sliding angle 7.4 ± 3.1°). Crucially, the mesh framework acted as mechanical armor, protecting the re‐entrant structures from abrasion, enabling the surface to retain its liquid‐repellent properties even after 100 abrasion cycles under 12.3 kPa pressure—a durability breakthrough compared to conventional re‐entrant surfaces. Furthermore, the SHM‐R surface demonstrates robust underwater plastron stability, achieving a ≈100% improvement in water pressure resistance while maintaining stable plastron coverage under pressure fluctuations. The excellent gas spreading behavior of SHM‐R enables capillary‐driven air self‐suction to rapidly replenish damaged plastrons. This work provides an important insight for the scalable design of robust super‐repellent surfaces.