Background <p>Interlocking metasurfaces (ILMs) are an emerging joining technology that creates customizable, scalable, adaptable, and non-permanent joints with high mechanical integrity. This is achieved via arrays of autogenous mating features that transmit force and constrain motion in one or more directions between adjoining bodies.</p> Objective <p>This study examines the effects of repetitive latching/unlatching cycles on ILM performance, with a focus on the run-in period and a transition to quasi-stable steady-state latching.</p> Methods <p>We examined the effects of manufacturing method, corresponding surface finish, and dimensional tolerances on the run-in behavior by studying ILMs produced using laser powder bed fusion (LPBF) additive manufacturing (AM), AM followed by electropolishing (AM + EP), and wire electric discharge machining (EDM). For each scenario, the evolution in insertion force and electrical contact resistance was observed over a period of 500 latch/unlatch cycles. Additionally, changes in surface morphology and surface chemistry were compared before and after the cycling.</p> Results <p>The outcome showed that each scenario evolved differently: with regard to insertion forces, only the AM + EP condition exhibited clear steady-state behavior after run-in whereas the other two scenarios continued to evolve over the 500 cycle duration; with regard to contact resistance, all three scenarios showed a trend of increasing resistance with cycling.</p> Conclusion <p>Manufacturing method, surface finish, and tolerance dictated the run-in period’s duration. This first study on the effects of run-in on repeated ILM usage lays the groundwork for subsequent detailed studies on tribological evolution or improvements in ILM performance via lubricants, coatings and surface treatments.</p>