Utilizing a Diffractive Focus Beam Shaper to Enhance Pattern Uniformity and Process Throughput during Direct Laser Interference Patterning

Uniform periodic microstructure formation over large areas is generally challenging in Direct Laser Interference Patterning (DLIP) due to the Gaussian laser beam intensity distribution inherent to most commercial laser sources. In this work, a diffractive fundamental beam-mode shaper (FBS) element is implemented in a four-beam DLIP optical setup to generate a square-shaped top-hat intensity distribution in the interference volume. The interference patterns produced by a standard configuration and the developed setup are measured and compared. In particular, the impact of both laser intensity distributions on process throughput as well as fill-factor is investigated by measuring the resulting microstructure height with height error over the structured surface. It is demonstrated that by utilizing top-hat-shaped interference patterns, it is possible to produce on average 44.8% deeper structures with up to 60% higher homogeneity at the same throughput. Moreover, the presented approach allows the production of microstructures with comparable height and homogeneity compared to the Gaussian intensity distribution with increased throughput of 53%.

Structuring and functionalization of non-metallic materials using direct laser interference patterning: a review

Direct laser interference patterning (DLIP) is a laser-based surface structuring method that stands out for its high throughput, flexibility and resolution for laboratory and industrial manufacturing. This top–down technique relies on the formation of an interference pattern by overlapping multiple laser beams onto the sample surface and thus producing a periodic texture by melting and/or ablating the material. Driven by the large industrial sectors, DLIP has been extensively used in the last decades to functionalize metallic surfaces, such as steel, aluminium, copper or nickel. Even so, DLIP processing of non-metallic materials has been gaining popularity in promising fields such as photonics, optoelectronics, nanotechnology and biomedicine. This review aims to comprehensively collect the main findings of DLIP structuring of polymers, ceramics, composites, semiconductors and other non-metals and outline their most relevant results. This contribution also presents the mechanisms by which laser radiation interacts with non-metallic materials in the DLIP process and summarizes the developed surface functions and their applications in different fields.

Detection and analysis of photo-acoustic emission in Direct Laser Interference Patterning

Functional laser texturing by means of Direct Laser Interference Patterning is one of the most efficient approaches to fabricate well-defined micro textures which mimic natural surfaces, such as the lotus effect for self-cleaning properties or shark skin for reduced friction. While numerous technical and theoretical improvements have been demonstrated, strategies for process monitoring are yet to be implemented in DLIP, for instance aiming to treat complex and non-plane surfaces. Over the last 35 years, it has been shown that the sound pressure generated by a laser beam hitting a surface and producing ablation can be detected and analysed using simple and commercially available transducers and microphones. This work describes the detection and analysis of photo-acoustic signals acquired from airborne acoustic emission during DLIP as a direct result of the laser–material interaction. The study includes the characterization of the acoustic emission during the fabrication of line-like micro textures with different spatial periods and depths, the interpretation the spectral signatures deriving from single spot and interference ablation, as well as a detailed investigation of the vertical extent of the interference effect based on the ablated area and its variation with the interference period. The results show the possibility to develop an autofocusing system using only the signals from the acoustic emission for 3D processing, as well as the possibility to predict deviations in the DLIP processing parameters.

Metallography and Biomimetics – Or New Surfaces Without Chemistry?

Fingerprints, a butterfly’s wings, or a lotus leaf: when it comes to surfaces, there is no such thing as coincidence in animated nature. Based on their surfaces, animals and plants control their wettability, their swimming resistance, their appearance, and much more. Evolution has optimized these surfaces and developed a microstructure that fits every need. It is all the more astonishing that, with regard to technical surfaces, man confines himself to random roughnesses or “smooth” surfaces. It is surely not a problem of a lack of incentives: structured surfaces have already provided evidence of optimizing friction and wear [1, 2, 3, 4], improving electrical contacts [5, 6], making implants biocompatible [7, 8], keeping away harmful bacteria [9], and much more. How come we continue counting on grinding, polishing, sandblasting, or etching? As so often, the problem can be found in economic cost effectiveness. It is possible to produce interesting structures such as those of the feather in Fig. 1. However, generating fine structures in the micro and nanometer range usually requires precise processing techniques. This is complex, time-consuming, and cannot readily be integrated into a manufacturing process. Things are different with Direct Laser Interference Patterning, DLIP) [10, 11]. This method makes use of the strong interference pattern of overlapped laser beams as a “stamp” to provide an entire surface area with dots, lines, or other patterns – in one shot. It thus saves time, allows for patterning speeds of up to 1 m2/min and does it without an elaborate pre- or post-treatment [10, 12]. The following article intends to outline how the method works, which structures can be generated, and how the complex multi-scale structures that nature developed over millions of years can be replicated in only one step.

Simultaneous Micro-Structuring and Surface Smoothing of Additive Manufactured Parts Using DLIP Technique and Its Influence on the Wetting Behaviour

It is well known that the surface topography of a part can affect its function as well as its mechanical performance. In this context, we report on the surface modification of additive manufactured components made of Titanium 64 and Scalmalloy®, using Direct Laser Interference Patterning technique. In our experiments, a nanosecond-pulsed near-infrared laser source with a pulse duration of 10 ns was used. By varying the process parameters, periodic structures with different depths and associated roughness values are produced. Additionally, the influence of the resultant morphological characteristics on the wettability behaviour of the fabricated textures is investigated by means of contact angle measurements. The results demonstrated a reduction of the surface roughness of the additive manufactured parts (in the order of some tens of micrometres) and simultaneously the production of well-defined micro-patterns (in the micrometre range), which allow the wettability of the surfaces from 26° and 16° up to 93° and 131° to be tuned for Titanium 6Al 4V and Al-Mg-Sc (Scalmalloy®), respectively.