Lithography has come a long way in recent years, with many innovative methods being developed for creating micro and nanostructures in thin films. Despite the progress, most processes still involve multiples steps that can be time-consuming and high cost. Among these lithographic methods, electrohydrodynamic method is the most cost-effective method that is promising for the replication of numerous patterns with high-fidelity features over a large area.

The electrohydrodynamic (EHD) method is a process that creates structures using external electric field to control the flow of thin film. The thin fluid film in the capacitor device of the EHD process is fully driven towards the top electrode by the induced instabilities, leading to creating the desired structures in a small amount of time. Carefully controlling the parameters of the process leads to the production of a wide range of patterns simple line to complex structures with high uniform and precise patterns. The development of surface structures with controlled patterns has become increasingly important for enhancing surface properties of materials with potential applications.

What' s more, the use of unique structures on non-traditional substrates like flexible materials has opened up new possibilities such as flexibility and compatibility with wearable devices. The direct pattern transfer methods have certain limitations that must be taken into consideration. One such limitation is the requirement of conformal contact; the pattern can become damaged during the process. Instead of the traditional pattern transfer method, capillary peeling method is a trustworthy method to transfer unique surface structures on irregular surfaces without any conformal contact.

In this study, we report the combination of electrohydrodynamic patterning for high fidelity features and the capillary transfer method for transferring patterns on the desired surface, that address the current limitations in creating patterns on non-conventional substrates. By altering the electrode gap in the EHD patterning process, the density and shape of patterns can have a significant impact on the properties of the surface like wettability. With further research and development, coupling EHD-induced structures with the pattern transfer method can lead to potential applications in a variety of fields.