RMIT University researchers have developed a flexible plastic film that physically destroys viruses on contact by using engineered nanotextured surfaces, offering a chemical-free alternative to conventional disinfectants.
The film, made from acrylic and patterned with nanopillars, inactivated approximately 94% of human parainfluenza virus type 3 (hPIV-3) particles within one hour in laboratory tests, according to findings published in Advanced Science.
Unlike disinfectants that require dwell time and can degrade surfaces or contribute to antimicrobial resistance, this surface acts immediately through mechanical rupture of viral membranes when pathogens make contact.
The antiviral effect depends critically on the spacing between nanopillars, with optimal performance at about 60 nanometres apart; effectiveness declines sharply beyond 100 nanometres and is negligible at 200 nanometres, regardless of pillar height.
Researchers found that tightly packed nanopillars — whether spike-like or blunt — increase pressure on the viral envelope, stretching it past its breaking point, a mechanism confirmed through experiments mimicking nanostructures on insect wings.
This approach builds on over a decade of research initially aimed at creating germ-repelling surfaces, which unexpectedly revealed that certain topographies kill microbes through physical stress rather than chemistry.
The material is designed for scalability, using roll-to-roll manufacturing techniques compatible with existing industrial equipment, potentially enabling low-cost production for phone screens, hospital surfaces, and consumer products.
Study lead Samson Mah emphasized the film’s compatibility with current factory processes, noting it could be applied to everyday items without requiring harsh chemicals or special handling.
Co-author Elena Ivanova said the team is prepared to collaborate with industry partners to refine the technology for broad real-world use, particularly in healthcare and high-touch environments.
While testing has focused on enveloped viruses like hPIV-3, researchers plan to evaluate the film’s efficacy against non-enveloped viruses and curved surfaces where nanopillar spacing may vary.
The innovation addresses limitations of current antiviral coatings, such as those using copper or nanospikes, which rely on chemical degradation and can pose health or environmental risks over time.
How does this plastic film kill viruses without chemicals?
The film uses tightly spaced nanopillars that physically latch onto and stretch the viral membrane until it ruptures, inactivating the virus through mechanical force rather than chemical reaction.
Can this technology be manufactured at scale using current methods?
Yes, the film is made from flexible acrylic suitable for roll-to-roll production, allowing it to be made in large quantities with existing industrial equipment.
What types of surfaces could this antiviral film be applied to?
Potential applications include phone screens, keyboards, hospital tables, and other frequently touched surfaces in healthcare and public settings.
