Electrospray Crystallization of Stearic Acid: Effect of Processing Parameters on Wettability and Crystal Morphology

ABSTRACT

Stearic acid is a non‐toxic, biocompatible, and biodegradable compound, making it a highly promising candidate for the development of hydrophobic surfaces and coatings. Electrospray crystallization, a pivotal technique in materials science and surface engineering, has not been directly utilized with stearic acid as a hydrophobic precursor material. Therefore, in this research, Response surface methodology was employed to optimize the stearic acid coating by the electrospray crystallization process by investigating key operational parameters such as solid content, applied voltage, collector distance, and feed flow rate. These parameters were found to have a significant impact on the resultant contact angle, a critical measure of hydrophobicity in coatings. Scanning electron microscopy characterizations conducted at key experimental stages further revealed how these parameters influenced crystal size and morphology. This work provides fundamental knowledge into how electrospray operational parameters influence crystal properties, enabling the rational design of hydrophobic surfaces. These findings suggest potential applicability in areas such as self‐cleaning materials, anti‐fouling coatings, membranes, and microfluidic devices, although further studies involving dynamic wettability and durability are required to validate these applications.