Unconventional localization prior to wrinkles and controllable surface patterns of film/substrate bilayers through patterned cavities

Wrinkle formation followed by sharp strain localization is commonly observed in compressed stiff film/soft substrate systems. However, cavities or defects beneath the film may directly trigger the formation of local ridges and then folding configurations at a relatively small compressive strain, and a mixture of wrinkles and folds upon further compression. The morphological transition is different than those of defect-free substrates. Numerical simulations of continuously compressed bilayer with pre-patterned cavities are carried out to elucidate the transition mechanism of surface patterns. Parallel experiments of cavities-patterned bilayer prototypes by 3D-printing are also performed to validate the findings in simulations. A rich diversity of periodic surface topologies, including overall spreading waves, localizations, saw-like and co-existing features of folds and wrinkles can be obtained by varying the diameter, depth and spacing of cavities, which provides a potential approach to engineer various surface patterns for applications.