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Changing the surface properties (i.e., roughness or friction) can be instrumental for many applications but can be a complex and resource-intensive process. In this paper, we demonstrate a novel process of controlling the friction of a continuous rod by delivering inorganic microparticles. A standardized continuous particle transfer protocol has been developed in our laboratory for depositing particles from a liquid carrier system (LCS) to the cylindrical rod substrate. The particle transfer process can produce controllable and tunable surface properties. Polymeric binder is used to deliver the particles as asperities over the rod substrate and by controlling their size, shape, and distribution, the coefficient of friction of the rod is determined. Tabletop experiments are designed and performed to measure the friction coefficient following the Capstan equation. The entrained particles on the substrate will create size- and shape-based asperities, which will alter the surface morphology toward the desired direction. Both oblique and direct quantitative measurements are performed at different particles and binder concentrations. A systematic variation in the friction coefficient is observed and reported in the result section. It is observed from the capstan experiment that adding only 1% irregular shaped particles in the suspension changes the friction coefficient of the rods by almost 115%. The proposed friction control technique is a simple scale-up, low-cost, low-waste, and low-energy manufacturing method for controlling the surface morphology.

In manufacturing industries, spherical micro-particles are commonly used as (e.g., brazing powder, metal filler, and 3D printing powder) which are produced with droplet-based particle fabrication techniques. Such processes create spherical morphology but introduce polydispersity and follow a continuous exponential pattern commonly expressed with Rosin-Rammler expression. Sorting those micro-particles in a narrower size range is an important but difficult, costly, and challenging process. Here we demonstrate the successful separation of the particles from a poly-disperse mixture with a particle volume fraction of 10% by dipping process. Nickel-based micro-particles (avg. dia. 5.69 μm) are added in a binder-based liquid carrier system. To encounter the gravitational force, external kinetic energy in the form of agitation is applied to ensure the uniform dispersion of the particles. The cylindrical substrate is prepared and dipped in the ‘pseudo suspension’ to separate the particles by adhering to it. The substrate is dried, and images are taken to characterize the separated particles using image J software. A clear size distribution can be observed which is also plotted. Additionally, a relationship between the process parameter and sorted particles has been established. The proposed method is quick, controllable, and easy to implement, which can be a useful tool for sorting wide-range poly-disperse particles.