Abstract <p>Dropwise condensation of water vapor is crucial for industrial processes such as thermal management, power generation, air conditioning, and dew/fog harvesting. Continuous dropwise condensation requires surfaces with optimized droplet nucleation and efficient departure, relying on heterogeneous wettability and surface engineering. This study introduces a simple, cost-effective, and environmentally friendly method to fabricate hierarchical micro–nanoroughened surfaces on aluminum alloy, copper, and zinc substrates. By combining sandblasting for microscale roughness and hot water treatment (HWT) for nanoscale features, the process overcomes limitations of existing substrate-specific or costly fabrication methods. The resulting surfaces exhibit superhydrophobic properties with water contact angles up to 162°, enhancing droplet nucleation and departure. Growth exponent analysis (α ≈ 1/3) confirms efficient droplet departure, sustaining condensation cycles. These hierarchical structures outperform smooth and single-roughness surfaces, offering scalable, versatile solutions for condensation-driven applications, paving the way for improved energy efficiency and operational performance across various industries.</p> Impact statement <p> <i>Scientific impact.</i>This study advances the field of surface engineering by introducing a scalable and environmentally friendly method to fabricate hierarchical superhydrophobic surfaces on metals. The results provide new insights into optimizing dropwise condensation, with water contact angles exceeding 160° and growth exponent analysis (α ≈ 1/3) confirming enhanced condensation dynamics. These findings offer a significant leap forward in designing efficient heat-transfer surfaces for various applications.</p> <p> <i>Practical applications.</i> This study advances the field of surface engineering by introducing a scalable and environmentally friendly method to fabricate hierarchical superhydrophobic surfaces on metals. The results provide new insights into optimizing dropwise condensation, with water contact angles exceeding 160° and growth exponent analysis (α ≈ 1/3) confirming enhanced condensation dynamics. These findings offer a significant leap forward in designing efficient heat-transfer surfaces for various applications.</p> <p> <i>Policy relevance.</i> The environmentally friendly fabrication process, which avoids toxic chemicals and high-energy consumption, aligns with global policy efforts toward sustainable engineering and green technology adoption. It supports industrial practices aimed at reducing carbon footprints and optimizing resource utilization.</p> <p><i>Societal benefit.</i> This research directly addresses challenges in water and energy resource management. By improving the efficiency of condensation technologies, the study contributes to enhancing access to clean water and sustainable energy solutions, addressing global needs for resource sustainability.</p> Graphical abstract <p></p>