Bio‐Inspired Hybrid Laser Direct Writing of Interfacial Adhesion for Universal Functional Coatings

Abstract Enhancing interfacial adhesion between functional coatings and target surfaces facilitates long‐term stable service by mitigating interferences of mechanical mismatches. Design of mechanical interlocks affords an effective strategy to strengthen the interfacial bonding with durability and compatibility, but the in‐depth investigations are still lacked. Herein, a gecko‐inspired hierarchical strategy realized by hybrid laser direct writing is proposed, which incorporates an armored frame scale for surface protection and a riveted anchor scale for interlocks. Such dual‐scale configurations endow the functional coatings with the stronger adhesion to the targets than the pristine and mono‐scale cases, resulting in 2 orders of magnitude enhancement resistant to tape peeling tests. Utilizing this scheme, a laser‐induced integrated deicing system is in situ manufactured on thermoplastics, primarily comprising superhydrophobic structures, carbon‐based sensors as well as adhesive copper (Cu) interconnects and heaters, where Cu‐based devices exhibit superior resistance to water impacts and stress fatigue. Interfacing with signal processing modules, such an all‐in‐one system demonstrates real‐time temperature monitoring and high efficiency in deicing (4.24 folds faster than the control group). The facile route for intensified adhesion holds promise in the interfaces within advanced equipment and under harsh scenarios.