Breaking the Ice: From Fundamentals to Next-Generation Ice-Shedding Surfaces

Hadi Ghasemi

11TH Thermal and Fluids Engineering Conference (Hybrid) In person at Arizona State University, Tempe, AZ, USA And partially online virtual via Zoom and Whova

Icing affects a wide range of systems-from aircraft and drones to marine structures, power lines, and energy infrastructure-where it degrades performance, disrupts operations, and creates major safety risks. Despite its broad impact, developing coatings that can both shed ice effectively and endure harsh conditions remains a major materials challenge, as low ice adhesion and high durability rarely coexist. Here, we present the physics of ice–material interactions and introduce new design strategies that overcome this trade-off, enabling a new generation of highly durable, high-performance ice-shedding coatings. We tackle this long-standing challenge by introducing fracture-controlled surfaces (FCSs), a new materials paradigm that simultaneously enables ultra-low ice adhesion and unprecedented mechanical durability. In FCSs, the chemistry and architecture of the material are engineered so that interfacial cracks nucleate at predefined locations and propagate rapidly with minimal energy loss. By directing how and where fracture occurs, FCSs shed ice with remarkably low force while maintaining durability improvements of more than three orders of magnitude over existing materials. We also establish a predictive mathematical framework that quantifies solid–surface adhesion on FCSs, providing a foundation for the rational design and synthesis of next-generation ice-shedding materials. We also examine the practical challenges and real-world experiences involved in bringing this technology from the lab to the market. This includes navigating material scale-up and long-term field testing. Along the way, we share the key lessons, unexpected obstacles, and success stories that have shaped the commercialization journey of this technology.