Researchers have engineered a flexible plastic film that physically dismantles viruses the moment they touch its surface, potentially transforming how hospitals and manufacturers approach contamination control.
The material works through a counterintuitive mechanism: microscopic structures called nanopillars coat the acrylic surface and mechanically grip viruses, stretching their outer membranes until they rupture. Unlike conventional antimicrobial surfaces that rely on chemical disinfectants or metal coatings, this approach uses pure mechanical force.
Scientists at RMIT University tested the film against human parainfluenza virus 3, which causes bronchiolitis and pneumonia. Within one hour, approximately 94 percent of virus particles were either torn apart or damaged beyond the point of reproduction. The findings appeared in Advanced Science.
Spacing Beats Height
A critical discovery emerged from the laboratory work: how tightly the nanopillars cluster together matters far more than their height. When nanopillars stand about 60 nanometers apart, multiple structures can simultaneously press against a single virus, overwhelming its membrane defenses. Doubling that spacing to 100 nanometers substantially weakened the effect, and 200-nanometer spacing rendered the surface nearly ineffective.
Study lead Samson Mah, a PhD candidate at RMIT, emphasized the team's focus on manufacturability. "Our mold can be adapted to roll-to-roll manufacturing, meaning antiviral plastic films could be produced at scale with existing factory equipment," he said.
The choice of acrylic and low-cost materials reflects a pragmatic approach distinct from earlier rigid nanostructures made from silicon. Flexible plastic can be integrated into phone screens, keyboards, hospital tables, and medical equipment without requiring industrial retooling. Traditional antiviral coatings from metals or silicon lacked this scalability.
The mechanical principle extends beyond the specific virus tested. Earlier research demonstrated that rigid nanospike silicon could disrupt viruses, but this work shows that both sharp and blunt nanostructures work when spaced correctly. The implication is clear: density and arrangement trump geometry.
Researchers now plan to test the film against non-enveloped viruses, which lack the fatty membrane that makes hPIV-3 vulnerable to nanopillar attack. They also want to assess performance on curved surfaces, since bending can alter the spacing between structures.
Distinguished Professor Elena Ivanova, a study co-author, signaled readiness to partner with manufacturers. "We think this texturing is a strong candidate for everyday use and we're ready to partner with companies to refine it for large-scale manufacturing," she said.
Author Jessica Williams: "This solves a real problem that chemical sprays and metal coatings couldn't quite crack, and the fact it works at manufacturing scale without expensive equipment is the real story here."
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