Research from RMIT University has found that a flexible plastic film designed with ultra-fine nanoscale textures can mechanically destroy viruses on contact, pointing to a potentially scalable manufacturing approach for antiviral surfaces used in healthcare and consumer products.
Published in Advanced Science, the study outlines how a thin acrylic film textured with nanopillars can rupture virus particles through physical force rather than chemical agents.
The team reports that the surface killed about 94% of tested virus particles within one hour in laboratory conditions using the human parainfluenza virus 3 (hPIV-3).
Study lead author and PhD candidate Samson Mah from RMIT University said the material is designed with practicality in mind, noting its compatibility with existing industrial production methods.
“We could one day have surfaces like phone screens, keyboards and hospital tables covered with this film, killing viruses on contact without using harsh chemicals,” he said. “Our mould can be adapted to roll-to-roll manufacturing, meaning antiviral plastic films could be produced at scale with existing factory equipment.”
The researchers found that performance depended heavily on the spacing of nanopillars rather than their height. According to Mah, tighter spacing significantly improved effectiveness.
“By tweaking the spacing and height of the nanopillars, we discovered how tightly they are packed together is far more important than how tall they are for breaking viruses apart,” he said. He added that closely packed structures increase pressure on viral surfaces, leading to rupture.
The most effective configuration featured nanopillars spaced about 60 nanometres apart. Wider spacing reduced performance, with antiviral activity declining at 100 nanometres and becoming ineffective at around 200 nanometres.
The study also suggests that both spike-like and blunt nanoscale features can disrupt viruses when densely arranged.
The work so far has focused on enveloped viruses such as hPIV-3, which have a fragile outer membrane. Researchers said further testing is planned on non-enveloped viruses, which are typically harder to inactivate, as well as on curved surfaces where nanoscale spacing may change.
Study co-author Distinguished Professor Elena Ivanova from RMIT University said the findings point to potential real-world applications and industry collaboration.
“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.
