Surface roughness significantly modifies the liquid film thickness entrained when dip coating a solid surface, particularly at low coating velocity. Using a homogenization approach, we present a predictive model for determining the liquid film thickness coated on a rough plate. A homogenized boundary condition at an equivalent flat surface is used to model the rough boundary, accounting for both flow through the rough texture layer, through an interface permeability term, and slip at the equivalent surface. While the slip term accounts for tangential velocity induced by viscous shear stress, accurately predicting the film thickness requires the interface permeability term to account for additional tangential flow driven by pressure gradients along the interface. We find that a greater degree of slip and interface permeability signifies less viscous stress that would promote deposition, thus reducing the amount of free film coated above the textures. The model is found to be in good agreement with experimental measurements, and requires no fitting parameters. Furthermore, our model may be applied to arbitrary periodic roughness patterns, opening the door to flexible characterization of surfaces found in natural and industrial coating processes.

We study the first contact of an emulsion drop impacting on a smooth solid surface. The lubricating air layer causes rapid deceleration of the bottom tip of the drop as it approaches first contact, causing a dimple in the drop surface. When the dispersed emulsion droplets are of higher density than the drop's continuous phase, the rapid deceleration (${\sim }10^5$ m s$^{-2}$) induces the formation of narrow spikes extruding out of the free surface. These spikes form when the impact Weber number exceeds a critical value ${\simeq }10$. Time-resolved interferometric imaging, at rates up to 7 million frames per second, shows the emergence and shape of these spikes leading to the local contacts with the solid. We characterize the tip curvature and capillary pressure affecting their dynamics as they emerge and can touch the substrate before the main outer ring of contact.