Tunable formation of ordered wrinkles in metal films with controlled thickness gradients deposited on soft elastic substrates.

Controlled wrinkled surface is useful for a wide range of applications, including flexible electronics, smart adhesion, wettability, stamping, sensoring, coating, and measuring. In this work, thickness-gradient-guided spontaneous formation of ordered wrinkling patterns in metal films deposited on soft elastic substrates is revealed by atomic force microscopy, theoretic analysis, and simulation. It is observed that in the thicker film region, broad cracks form, and the film surface remains flat. In the thinner film region, the cracks attenuate along the direction of the thickness decrease, and various wrinkle patterns including branched stripes, herringbones, and labyrinths can coexist. The interplay between the residual compression and the thickness gradient leading to the formation of such wrinkling patterns is discussed based on a nonlinear wrinkling model. The simulated wrinkling patterns as well as the variation trends of the wrinkle wavelength and amplitude along the gradient direction are in good agreement with the experimental observations. The report in this work could promote better understanding and fabrication of such ordered wrinkling patterns by tunable thickness gradient.