A conformal coating process is presented to transform surfaces with inherent micro-morphology into superhydrophobic surfaces with hierarchical surface structure using wet chemical spray casting. Nanocomposite coatings composed of zinc oxide nanoparticles and organosilane quaternary nitrogen compound are dispersed in solution for application. The coating is applied to a micro-patterned polydimethylsiloxane substrate with a regular array of cylindrical microposts as well as a surface with random micro-structure for the purpose of demonstrating improved non-wettability and a superhydrophobic state for water droplets. Coating surface morphology is investigated with an environmental scanning electron microscope and surface wettability performance is characterized by static and dynamic contact angle measurements. (C) 2010 Elsevier B.V. All rights reserved.