Adhesive Interlayer Research Articles

Amyloid Proteins Adhesive for Slippery Liquid-Infused Porous Surfaces.

Biomimetic slippery liquid-infused porous surfaces (SLIPS) have emerged as a promising solution to solve the limitations of superhydrophobic surfaces, such as inadequate durability in corrosion protection and a propensity for frosting. However, the challenge of ensuring strong, lasting adhesion on diverse materials to enhance the durability of the lubricant layer remains. The research addresses this by leveraging amyloid phase-transitioned lysozyme (PTL) as an adhesive interlayer, conferring stable attachment of SLIPS across a variety of substrates, including metals, inorganics, and polymers. The silica-textured interface robustly secures the lubricant with a notably low sliding angle of 1.15°. PTL-mediated adhesion fortifies the silicone oil attachment to the substrate, ensuring the retention of its repellent efficacy amidst mechanical stressors like ultrasonication, water scrubbing, and centrifugation. The integration of robust adhesion, cross-substrate compatibility, and durability under stress affords the PTL-modified SLIPS exceptional anti-fouling, anti-icing, and anti-corrosion properties, marking it as a leading solution for advanced protective applications.

Enhancing adhesive interlayer performance with waste tire rubber and amorphous poly alpha olefin compound modified asphalt

Insufficient bonding performance in interlayers is a key factor in the deterioration of bridge deck pavements. This study evaluates the bonding and durability of Waste Tire Rubber (WTR)/Amorphous Poly Alpha Olefin (APAO) modified asphalt compared to the commonly used Styrene-Butadiene-Styrene (SBS) modified asphalt. We conducted shear and pull tests to analyze how different bonding processes and the texture depth of the concrete surface affect bonding performance. The research also assessed the durability of the adhesive layer under conditions such as temperature fluctuations, water immersion, and aging. Results show that the choice of bonding method significantly impacts adhesive performance, with the coating bond method being superior to the crushed stone bond method. A concrete surface texture depth of 0.88 mm was identified as optimal for improving adhesive performance. Moreover, the WTR/APAO adhesive interlayer provided better adhesive and durability performance than the SBS adhesive interlayer under conditions of temperature fluctuations and water immersion. Based on these findings, the study recommends using the coating bond process and 15%WTR + 4%APAO modified asphalt for the adhesive interlayer.

Biomimetic 3D printed spicule-like structure composite of organic material/rigid resin cylinders with highly enhanced strength and toughness

Recently, the microstructure of Euplectella Aspergillum (EA) marine sponges, called spicule, has been recognized as one of the attractive biological microstructures with superior flexural strength and toughness. The lack of studies to mimic this structure motivated us to design rods with a spicule-inspired structure with improved mechanical properties. In this study, spicule-inspired structures were produced by the stereolithography (SLA) method. Different adhesives were infiltrated between the layers to evaluate the effect of organic materials on their mechanical properties. The effect of the curing process on the mechanical properties of spicule-inspired structures with and without organic (adhesive) interlayers was evaluated. Also, the effects of various adhesives, different spaces between the cylinders, and ultraviolet (UV) curing on mechanical properties were evaluated. The results showed that the flexural strength of spicule-inspired structures was improved by about 71 % after curing the samples at 60 °C and under UV light for 30 min and aging in the air for 30 days. Samples including Titebond adhesive (SP1-1.1) showed a higher amount of peak load (129.5 ± 17.21 N) and extension (22.3 ± 3.12 mm) compared to those counterparts without any organic layers (SP-1.1) with a peak load of 101.5 ± 13.34 N and extension of 19.1 ± 1.32 mm. Adding the adhesive layers between the rigid cylinders enhanced the flexibility and strength of the structures. It was found that the curing time by UV after 30 days of aging did not affect the mechanical properties of the samples.

Three‐dimensional graphene architecture reinforced epoxy composite with double‐sided adhesive molybdenum disulfide transition interlayer for maintaining excellent interfacial and tribological properties

AbstractThree‐dimensional graphene architecture (3DGA) as reinforcement with successive reinforcement effect has attracted intense attention in the field of polymer composites, while 3DGA also faces the disadvantages of weak interfacial adhesion with matrices. The surface decoration of 3DGA with molybdenum disulfide (3DGA@MoS2) further promoted the diffusion and penetration of epoxy molecular for 3DGA network with the aid of resin transfer molding (RTM) technic. The MoS2 transition nanolayer not only forms covalent bonding with 3DGA but mechanical interlocks with epoxy, which effectively improved the interface combination in composite. Compared with neat epoxy, the glass transition temperature (Tg) and tensile strength increased by 18°C and 58.6%, as well as the average friction coefficient and wear rate decreased by 84% and 89%, respectively, by low loading of only 2 wt% 3DGA@MoS2. Hence, the 3D graphene modified strategy by surface decoration provides a new insight for manufacturing high‐performance epoxy‐graphene composites with excellent tribological properties.Highlights A highly ordered and interconnected 3DGA reinforcement was fabricated. MoS2 serves as interlayer, forming covalent bond and mechanical interlock. Incorporation of 3DGA@MoS2 enables rapid heat conduction and load transfer. Bi‐interpenetrating 3D structure/polymer network endows good wear resistance. Improved comprehensive properties ascribe to strong interface adhesion.

Adhesive-free bonding for hetero-integration of InP based coupons micro-transfer printed on SiO2 into Complementary Metal-Oxide-Semiconductor backend for Si photonics application on 8″ wafer platform

Micro-Transfer printing (µTP) is a promising technique for hetero-integration of III-V materials into Si-based photonic platforms. To enhance the print yield by increasing the adhesion between the III-V material and Si or SiO2 surface, an adhesion promoter like Benzocyclobutene is typically used as interlayer. In this work, we demonstrate µTP of InP based coupons on SiO2 interlayer without any adhesive interlayer and investigate the mechanism of adhesive free bonding. Source coupons are InP-based coupon stacks on a sacrificial layer that is removed by a chemical wet etch with FeCl3. For the target we fabricated amorphous-Si waveguides on 8″ wafer encapsulated by a High Density Plasma SiO2 which was planarized by a chemical mechanical polishing procedure. We used O2 plasma to activate both source and target to increase adhesion between coupon and substrate. To get a better understanding of the bonding mechanism we applied several surface characterization methods. Root mean square roughness of InP and SiO2 was measured by atomic force microscopy before and after plasma activation. The step height of the micro-transfer printed source coupon on the target wafer is estimated by optical step profiler. We used Raman peak position mappings of InP to analyze possible strain and contact angle measurements on SiO2, before and after plasma activation to observe a change in the hydrophilicity of the surface. X-ray Photoelectron Spectroscopy analysis was used to characterize the surface energy states of P2p, In3d, O1s for InP source and Si2p, O1s for SiO2 target. Our results demonstrate direct bonding of InP coupons by means of µTP without the need of a strain-compensation layer. In this way, a promising route towards Complementary Metal-Oxide-Semiconductor compatible use of µTP for the hetero-integration of InP is provided.

A facile cellulose finishing strategy through in-situ growth of sliver-doped manganese dioxide assisted by amine-quinone for improving indoor living quality

Nowadays, various harmful indoor pollutants especially including bacteria and residual formaldehyde (HCHO) seriously threaten human health and reduce the quality of public life. Herein, a universal substrate-independence finishing approach for efficiently solving these hybrid indoor threats is demonstrated, in which amine-quinone network (AQN) was employed as reduction agent to guide in-situ growth of Ag@MnO2 particles, and also acted as an adhesion interlayer to firmly anchor nanoparticles onto diverse textiles, especially for cotton fabrics. In contrast with traditional hydrothermal or calcine methods, the highly reactive AQN ensures the efficient generation of functional nanoparticles under mild conditions without any additional catalysts. During the AQN-guided reduction, the doping of Ag atoms onto cellulose fiber surface optimized the crystallinity and oxygen vacancy of MnO2, providing cotton efficient antibacterial efficiency over 90 % after 30 min of contact, companying with encouraging UV-shielding and indoor HCHO purification properties. Besides, even after 30 cycles of standard washing, the Ag@MnO2-decorated textiles can effectively degrade HCHO while well-maintaining their inherent properties. In summary, the presented AQN-mediated strategy of efficiently guiding the deposition of functional particles on fibers has broad application prospects in the green and sustainable functionalization of textiles.

Polydopamine as a Materials Platform to Promote Strong and Durable Interfaces in Thermoplastic Polymer‐Titanium Joints

AbstractJoining thermoplastic polymers (TPMs) and metals to form lightweight hybrid structures is of growing industrial and commercial importance. The performance of such materials relies on the bonding strength and endurance of the formed TPM–metal interfaces. The available joining technologies and the mechanisms that govern interfacial adhesion are reviewed in this contribution, highlighting thermal bonding as a commercially attractive joining method. By focusing on molecular interactions to optimize interfacial adhesion, the use of dopamine as a building block to form polydopamine (PDA) based adhesive interlayers in such interfaces is discussed. This work also highlights the potential of PDA to be applied as a load‐bearing adhesive—a notion considered to date unfeasible.

Sustainable design of high-performance multifunctional carbon electrodes by one-step laser carbonization for supercapacitors and dopamine sensors.

Laser carbonization is a rapid method to produce functional carbon materials for electronic devices, but many typical carbon precursors are not sustainable and/or require extensive processing for electrochemical applications. Here, a sustainable concept to fabricate laser patterned carbon (LP-C) electrodes from biomass-derived sodium lignosulfonate, an abundant waste product from the paper industry is presented. By introducing an adhesive polymer interlayer between the sodium lignosulfonate and a graphite foil current collector, stable, abrasion-resistant LP-C electrodes can be fabricated in a single laser irradiation step. The electrode properties can be systematically tuned by controlling the laser processing parameters. The optimized LP-C electrodes demonstrate a promising performance in supercapacitors and electrochemical dopamine biosensors. They exhibit high areal capacitances of 38.9 mF cm-2 in 1 M H2SO4 and high energy and power densities of 4.3 μW h cm-2 and 16 mW cm-2 in 17 M NaClO4, showing the best performance among biomass-derived LP-C materials reported so far. After 20 000 charge/discharge cycles, they retain a high capacitance of 81%. Dopamine was linearly detected in the range of 0.1 to 20 μM with an extrapolated limit of detection of 0.5 μM (S/N = 3) and high sensitivity (13.38 μA μM-1 cm-2), demonstrating better performance than previously reported biomass-derived LP-C dopamine sensors.

Si-containing interlayer using tetramethylsilene for diamondlike carbon film adhesion on low-alloy steel: The role of the interlayer deposition time

Diamondlike carbon (DLC) coatings provide interesting properties for industrial applications. However, the low adhesion of DLC coatings on any type of ferrous alloy compromises technological applications. One possible solution to this issue is the application of adhesion interlayers. The aim of this study is to investigate the adhesion of DLC films on low-alloy steel through the use of silicon-containing interlayers at different deposition times using tetramethylsilane. The role of time on the physical-chemical, microstructural, and tribological properties of the material system was evaluated. The interlayer thickness linearly increased and greater contributions of silicon bonds were measured as a function of the interlayer deposition time. Nevertheless, longer deposition times increased the roughness and defect ratio in DLC coatings. Although good enough adhesion for decorative applications was acquired, no drastic variation in the average critical load (∼4.2 N) for delamination was observed at different deposition times for the samples that achieved adhesion.

Transferrable Electrospinning Nanofiber Meshes as Strongly Adhered Scaffolds for Slippery Liquid-Infused Porous Surfaces.

Slippery liquid-infused porous surfaces (SLIPS) are self-healing protective coatings that can be made by infiltration of a porous scaffold with a chemically resistant oil. A popular method to apply a SLIPS coating is using electrospinning to deposit a nanofiber mesh onto the intended substrate. However, electrospinning only lightly deposits the nanofibers onto the intended substrate, so the coating detaches easily even when unintended. We report a simple, yet effective, solution to the adhesion problem. Electrospun nanofiber meshes are typically well entangled and cohesive, so they can be detached from the electrospinning target and transferred onto the final target. Using a thin layer of adhesive on the intended surface, the electrospinning mesh can be securely attached and infiltrated with protective oil to yield a more stable SLIPS coating. An adhered coating can be submerged under corrosive solution and repeatedly self-heal from damage to the same spot. With the electrospun nanofiber meshes' flexibility and stretchability, the meshes can be fitted around a wide range of targets including ones that are otherwise difficult to apply a nanofiber mesh on. The use of an adhesive interlayer between the nanofiber mesh and substrate is a simple solution to improve coating stability, and the solution facilitates application of SLIPS onto a broader range of substrates.

Roll-to-roll solvent-free manufactured electrodes for fast-charging batteries

Roll-to-roll solvent-free manufactured electrodes for fast-charging batteries

HYDROXYAPATITE/Si-DOPED TiN INTERLAYER COATINGS AS POTENTIAL CANDIDATES FOR SURFACE MODIFICATION OF MEDICAL-GRADE 316 LVM STAINLESS STEEL FOR BIOIMPLANT APPLICATIONS

Hydroxyapatite (HAp) was deposited by plasma spraying technique with TiSiN adhesive interlayer on the medical-grade 316 LVM stainless steel. The surface topographies of HAp and HAp/TiSiN were evaluated using X-ray diffraction (XRD), Raman spectroscopy, atomic force microscopy (AFM), scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). The important mechanical properties of the films such as hardness ([Formula: see text]) and elastic modulus ([Formula: see text]) were determined by the nanoindentation test. Lastly, the adhesion and anti-scratch behaviors of the films were evaluated by Rockwell-C indentation and nanoscratch test, respectively. The elemental analysis showed the values of Ca/P (at.%/at.%) ratio to be 1.80 and 1.59 in HAp and HAp/TiSiN coatings, respectively. The mechanical properties of HAp film with TiSiN interlayer were greatly improved from 1.23[Formula: see text][Formula: see text][Formula: see text]0.26[Formula: see text]GPa to 10.6[Formula: see text][Formula: see text][Formula: see text]1.12[Formula: see text]GPa for hardness and from 18[Formula: see text][Formula: see text][Formula: see text]3[Formula: see text]GPa and 29.8[Formula: see text][Formula: see text] 5[Formula: see text]GPa for elastic modulus, respectively. The results of the Rockwell-C indentation test showed a significant reduction in HAp coating delamination with TiSiN interlayer which can be categorized with HF2 or HF3 Daimler–Benz quality ranking. What is more, the nanoscratch profile of HAp coating showed wider scratch with evidence of deformation at the edges which got significantly reduced with the TiSiN interlayer. The results are suggestive of improved mechanical properties, viz. hardness and elastic modulus, and improved adhesion strength of HAp coating with TiSiN interlayer.

A linear two-dimensional mathematical model for thin two-layer plates with partial shear interaction, with a view towards application to laminated glass

This work presents a consistent derivation, from three-dimensional linear elasticity, of a two-dimensional mathematical model describing the bending and in-plane stretching behaviours, under a general system of quasi-static distributed loads and prescribed support displacements, of thin two-layer plates with partial shear interaction. This layerwise model is specifically tailored for the requirements posed by the analysis of laminated glass plates commonly used in building structures (consisting of two thin glass layers bonded together by an adhesive interlayer). Our approach, based on Podio-Guidugli’s method of internal constraints, avoids mutually contradictory assumptions (not uncommon in the literature on structural mechanics) and yields a complete two-dimensional characterisation of displacement, strain and stress fields that exactly satisfy the field equations of three-dimensional linear elasticity and the boundary conditions at the end faces. The choice of generalised variables is designed to bring to light the following fundamental conclusion and physical insight: the resulting two-dimensional boundary value problem is a combination of the equations of Kirchhoff and Mindlin plates (with specified rigidities).Two examples illustrate the application of the proposed model: (i) the cylindrical bending of plate strips and (ii) a family of problems with Navier-type analytical solution. The solutions exhibit continuity across the whole range of zero, partial and full interaction between the layers. Moreover, the Navier-type solutions are consistently in close agreement with the results of three-dimensional finite element analyses. On the contrary, analogous results previously reported in the literature exhibit considerable deviations. An explanation for these discrepancies is discussed in detail.

Tuning the Mechanical Behavior of Density-Graded Elastomeric Foam Structures via Interlayer Properties.

The concept of density-graded foams has been proposed to simultaneously enhance strain energy dissipation and the load-bearing capacities at a reduced structural weight. From a practical perspective, the fabrication of density-graded foams is often achieved by stacking different foam densities. Under such conditions, the adhesive interlayer significantly affects the mechanical performance and failure modes of the structure. This work investigates the role of different adhesive layers on the mechanical and energy absorption behaviors of graded flexible foams with distinct density layers. Three adhesive candidates with different chemical, physical, and mechanical characteristics are used to assemble density-graded polyurea foam structures. The mechanical load-bearing and energy absorption performances of the structures are evaluated under quasi-static and dynamic loading conditions. Mechanical tests are accompanied by digital image correlation (DIC) analyses to study the local strain fields developed in the vicinity of the interface. Experimental measurements are also supplemented by model predictions that reveal the interplay between the mechanical properties of an adhesive interlayer and the macroscale mechanical performance of the graded foam structures. The results obtained herein demonstrate that the deformation patterns and macroscale properties of graded foam composites can be tuned by selecting different bonding agents. It is also shown that the proper selection of an adhesive can be a practical way to address the strength–energy dissipation dichotomy in graded structures.

A reliable method by utilizing thermo-responsive palladium nanocomposite for fabricating Nickel coating on nylon 6 fabrics

Flexible conductive textiles are one of the best choices for smart textiles due to their comfortable wearing and good compliance with the human body. The great adhesion and durability of metal coatings onto substrate surfaces are important indicators for the high-performance requirements of smart textiles. The main bottleneck for the development of flexible conductive textiles is the poor adhesion between the metal coating and the substrate, so efforts have been made to improve it on a variety of fabrics. Herein, we reported a facile and economical method to fabricate flexible conductive fabrics using commercial nylon 6 fabrics as substrates. In brief, Styrene-co-N-Isopropylacrylamide/Pd (St-co-NIPAAm/Pd) nanocomposites acted as activators and adhesive interlayers for electroless plating to improve the adhesion of the nickel layer onto the nylon 6 surface. A highly conductive nylon 6 fabric was prepared by a coating of St-co-NIPAAm/Pd nanocomposite and followed by Ni-P electroless plating. The optimal electroless plating process parameters for fabricating adhesion-enhanced and highly reliable nickel coating were also investigated in the study. Its reliable conductivity and high durability mean it is promising for smart textiles, even via a series of repeated bending and washing tests. In addition, we explain the mechanism by which St-co-NIPAAm/Pd nanocomposites change at a temperature below or beyond the lower critical solution temperature (LCST). To sum up, the developed conductive nylon 6 fabric can lay the groundwork for the subsequent development of smart textiles.

Evaluation of Adhesion Properties of Thin Film Structure through Surface Acoustic Wave Dispersion Simulation.

A theoretical simulation study of the dispersion characteristic of the surface acoustic wave (Rayleigh wave) was conducted by modeling the adhesion interlayer with stiffness coefficients to evaluate the bonding properties of nano-scale thin film structures. For experimental validation, a set of thin film specimens were fabricated—637 nm, 628 nm, 637 nm, 600 nm, and 600 nm thick titanium (Ti) films were deposited on silicon (Si) (100) substrate using a DC Magnetron sputtering process with DC power from 28.8 W, 57.6 W, 86.4 W, 115.2 W, and 144 W. The thicknesses of the Ti films were measured using a scanning electron microscope (SEM). Surface acoustic wave velocity for each of the manufactured thin film specimens was measured by using a V(z) curve technique of a Scanning Acoustic Microscope. The measured velocity, transducer frequency, and thickness of the film were applied to dispersion characteristic simulation for a given stiffness coefficient to calculate adhesion strength of each specimen. To verify the simulation result, the adhesion force of each specimen was measured using a nano-scratch test and then compared with the calculated values from the dispersion characteristic simulation. The value of adhesion strength from the dispersion characteristic simulation and the value of adhesion force of the nano-scratch test were found to have a similar tendency according to the process variable of the thin film. The results demonstrated that the adhesion strength of a thin film could be evaluated quantitatively by calculating the dispersion characteristics with the adhesion interlayer stiffness model.

The influence of V addition on the structure, mechanical properties, and oxidation behaviour of TiAlSiN coatings deposited by DC magnetron sputtering

The influence of V content on the morphology, structure, hardness (H) and reduced Young's modulus (E), adhesion, and oxidation resistance of TiAlSiN coatings is investigated. The coatings were produced by DC reactive magnetron sputtering, with increasing V contents from 0, 4.8 and 11.0 at.%. All coatings exhibit a fcc type structure. The coating with 4.8 at.% of V shows the highest values of H and E, whereas the values are similar for the reference coating and the coating with 11.0 at.% of V. The coatings adhere well to the substrates and show a dense and compact columnar growth extending from the adhesive interlayer to the top surface of the coatings. The dynamic thermal gravimetric oxidation curves reveal that V additions decreases the onset point of oxidation significantly and degrades the oxidation resistance of the coatings. A dual oxide layer is formed on the top surface of the reference coating: an outer porous Ti–Al–O rich layer with plate-like features on the top, which classified to TiO2 (rutile and anatase) and Al2O3 phases, and an inner Ti–Si–O rich layer with Al depletion that identified as mixture of amorphous Si–O and Ti–Si–O protective oxides. The diffusion of V to the top surface governs the oxidation process of the V-containing coatings, i.e. increasing V concentration leads to disrupt the formation of the protective continuous oxide layers easily.

Experimental and cohesive zone modelling study on composite joining by co-curing and adhesive bonding for sheet moulding compound or carbon-fibre prepreg laminates

Material selection plays an important part in engineering as the chosen material impacts not only performance but also the final cost of a component. Engineering has evolved to a point in which it allows manipulation of base materials to meet specific design and functional requirements. The present work experimentally and numerically studies the adhesion of both sheet moulding compound composites, and carbon fibre reinforced composites, using the single-lap joint geometry. Two grades of sheet moulding compound were studied, and two bonding methods were used: co-curing and adhesive bonding. Numerical analysis by cohesive zone modelling, after estimating the adhesive and composite interlayer properties, enabled predicting the maximum load and fracture mode. The cohesive zone modelling results were accurate, and the best joining solution involved co-curing the CFRP adherends, while all sheet moulding compound adhesive joints failed to attain the full adhesives’ capacity due to premature substrate tensile failure.

Evaluation of the delamination performance of polyvinyl-butyral laminated glass by through-cracked tensile tests

The interfacial adhesion between the interlayer and glass plays a vital role in determining the safety and post-fracture behavior of PVB-laminated glass. To get a better understanding of the delamination behavior of PVB-laminated glass, a series of through-cracked tensile (TCT) tests were carried out. Influences of different PVB adhesion grades (TROSIFOL® BG R15 and BG R20), loading rates (3 mm/min and 300 mm/min), and interlayer thicknesses (0.76 mm, 1.52 mm, and 2.28 mm) were considered in the tests. Digital image correlation (DIC) technology was adopted to record the delamination process. The delamination length, strain distribution on the PVB interlayer as well as delamination angle, were obtained through DIC analysis. Based on the test results, three typical delamination modes, i.e., unstable delamination, stable delamination, and restricted delamination, were observed. The delamination mode is strongly dependent on the adhesion grade and loading rate. Furthermore, to evaluate the interfacial adhesion, energy release rates were calculated based on an analytical approach. The adhesion grade dominates the delamination performance of the PVB-laminated glass. The delamination length of BG R15-laminated glass is much larger than that of BG R20-laminated glass due to lower interfacial energy release rate and hence exhibits better deformability. With the increase of the loading rate, the energy release rate increases for both BG R15 and BG R20 interlayers. The influence of PVB thickness on the interfacial adhesion was insignificant. For the first time, the delamination angle was identified from DIC results, and the results were used to determine the interfacial fracture mode. The results from this study provide more detailed data on the PVB-glass interfacial adhesion properties and a reference for the post-fracture analysis of PVB-laminated glass.

On-Demand Manufacturing Capabilities of Mussels Enable Robust Adhesion to Geometrically Complex Surfaces.

Marine mussels have the remarkable ability to adhere to a variety of natural and artificial surfaces under hostile environmental conditions. Although the molecular composition of mussel adhesives has been well studied, a mechanistic understanding of the physical origins of mussels' impressive adhesive strength remains elusive. Here, we investigated the role of substrate geometry in the adhesive performance of mussels. Experimentally, we created substrates with differing surface properties using 3D printing and laser drilling and introduced these to mussels, which in turn adhered to the engineered surfaces via plaque-thread byssal structures. Tensile testing with in situ imaging was conducted to quantify the adhesion strength of the mussel plaques, and the microstructures of the mechanically deformed plaques were characterized using scanning electron microscopy. Our results reveal that the geometry of the surfaces has no significant impact on the detachment force and the strain, whereas the change in adhesion area leads to a different adhesion stress. Ultrastructural analysis confirms the expected presence of an open-cell foamy network coated with the cuticle. The observed detachment dynamics and failure mechanisms do vary depending on the substrate properties, suggesting the presence of substrate-dependent nonuniform stress distributions at the interface. Together, these results show mussels' remarkable ability to adapt to differing physical conditions and demonstrate the importance of the on-demand and in situ manufacturing of the stiff cuticle and relatively compliant adhesive interlayer. The resultant composite structure avoids the formation of prestress during the formation of the adhesive joint, provides conformability to the surface, and helps compensate for local bending interactions to maintain adhesive strength. Our findings suggest forward design strategies to improve adhesive performance on complex surfaces.