Direct Laser Interference Patterning: Tailoring of Contact Area for Frictional and Antibacterial Properties

Space biofilms - An overview of the morphology of Pseudomonas aeruginosa biofilms grown on silicone and cellulose membranes on board the international space station

Microorganisms' natural ability to live as organized multicellular communities - also known as biofilms - provides them with unique survival advantages. For instance, bacterial biofilms are protected against environmental stresses thanks to their extracellular matrix, which could contribute to persistent infections after treatment with antibiotics. Bacterial biofilms are also capable of strongly attaching to surfaces, where their metabolic by-products could lead to surface material degradation. Furthermore, microgravity can alter biofilm behavior in unexpected ways, making the presence of biofilms in space a risk for both astronauts and spaceflight hardware. Despite the efforts to eliminate microorganism contamination from spacecraft surfaces, it is impossible to prevent human-associated bacteria from eventually establishing biofilm surface colonization. Nevertheless, by understanding the changes that bacterial biofilms undergo in microgravity, it is possible to identify key differences and pathways that could be targeted to significantly reduce biofilm formation. The bacterial component of Space Biofilms project, performed on the International Space Station in early 2020, contributes to such understanding by characterizing the morphology and gene expression of bacterial biofilms formed in microgravity with respect to ground controls. Pseudomonas aeruginosa was used as model organism due to its relevance in biofilm studies and its ability to cause urinary tract infections as an opportunistic pathogen. Biofilm formation was characterized at one, two, and three days of incubation (37 °C) over six different materials. Materials reported in this manuscript include catheter grade silicone, selected due to its medical relevance in hospital acquired infections, catheter grade silicone with ultrashort pulsed direct laser interference patterning, included to test microtopographies as a potential biofilm control strategy, and cellulose membrane to replicate the column and canopy structure previously reported from a microgravity study. We here present an overview of the biofilm morphology, including 3D images of the biofilms to represent the distinctive morphology observed in each material tested, and some of the key differences in biofilm thickness, mass, and surface area coverage. We also present the impact of the surface microtopography in biofilm formation across materials, incubation time, and gravitational conditions. The Space Biofilms project (bacterial side) is supported by the National Aeronautics and Space Administration under Grant No. 80NSSC17K0036 and 80NSSC21K1950.

Investigation of asymmetry reduction for surface structuring and destructuring by laser remelting

Lasers are widely used for structuring metallic surfaces by ablating material. An alternative approach for laser structuring is surface structuring by laser remelting (WaveShape), which is based onthe continuous remelting of a thin surface layer using laser radiation while simultaneously modulating the laser power. The structures are generated by redistribution of the molten material. The structure height and the structure wavelength of periodic structures created using WaveShape can be precisely adjusted by the adaption of various process parameters. However, the structures produced are mostly asymmetrical. An asymmetric structure refers to a structure that is not symmetrical and is inclined in or against the scanning direction. In the context of this work, the asymmetry of the structures was significantly reduced through two different process adaptations. As a first adaption, a compensation term is added to the laser power modulation, which is calculated from the difference profile between a target profile and a structured profile. With this adaption, the shape deviation of an asymmetrical structure could be decreased by 66 %. Asymmetry can be reduced efficiently, although the difference profile required must be determined from a preliminary process step. As a second adaption, a modulation of the scanning speed is investigated with which shape deviation can be decreased by 40 %. Asymmetry is not as effectively prevented as when using the first adaption, but the adaption can be performed without the difference profile. Another aim was to investigate the destructuring, i.e. the removal and therefore smoothing, of asymmetric structures. Using the inverse laser power modulation for destructuring, the structure height of a symmetrical structure can be reduced by 91 % while the structure height of an asymmetric structure can be reduced by 68 %. To increase the efficiency of destructuring of an asymmetrical structure, iterative destructuring was investigated. With two iterations of destructuring, the structure height was reduced by 90 %. As a second approach for more efficient destructuring of asymmetric structures an adaption of the laser power modulation via a compensation term was investigated. The structure height could be reduced by 86 %. In summary, results show that asymmetry can be prevented when structuring with WaveShape and that asymmetric structures can be destructured efficiently.

Surface Modification of Brass via Ultrashort Pulsed Direct Laser Interference Patterning and Its Effect on Bacteria-Substrate Interaction

In recent decades, antibiotic resistance has become a crucial challenge for human health. One potential solution to this problem is the use of antibacterial surfaces, i.e., copper and copper alloys. This study investigates the antibacterial properties of brass that underwent topographic surface functionalization via ultrashort pulsed direct laser interference patterning. Periodic line-like patterns in the scale range of single bacterial cells were created on brass with a 37% zinc content to enhance the contact area for rod-shaped Escherichia coli (E. coli). Although the topography facilitates attachment of bacteria to the surface, reduced killing rates for E. coli are observed. In parallel, a high-resolution methodical approach was employed to explore the impact of laser-induced topographical and chemical modifications on the antibacterial properties. The findings reveal the underlying role of the chemical modification concerning the antimicrobial efficiency of the Cu-based alloy within the superficial layers of a few hundred nanometers. Overall, this study provides valuable insight into the effect of alloy composition on targeted laser processing for antimicrobial Cu-surfaces, which facilitates the thorough development and optimization of the process concerning antimicrobial applications.

Surface Structuring by Laser Remelting (WaveShape): Microstructuring of Ti6Al4V for a Small Laser Beam Diameter and High Scan Speeds

The appearance of a surface is a crucial characteristic of a part or component. Laser-based micromachining gets increasingly important in generating tailored surface topographies. A novel structuring technique for surface engineering is surface structuring by laser remelting (WaveShape), in which surface features are created without material loss. In this study, we investigated the evolution of surface topographies on Ti6Al4V for a laser beam diameter of 50 µm and scan speeds larger than 100 mm/s. Surface features with aspect ratios (ratio of height to width) of almost 1:1 were achieved using the WaveShape process. Furthermore, wavelengths smaller than 500 µm could be effectively structured using scan speeds of up to 500 mm/s. The experimental results showed further that the efficiency of the WaveShape process in terms of achieved structure height per unit time significantly increases for high scan speeds.

Peptidic biofunctionalization of laser patterned dental zirconia: A biochemical-topographical approach

A dual approach employing peptidic biofunctionalization and laser micro-patterns on dental zirconia was explored, with the aim of providing a flexible tool to improve tissue integration of restorations. Direct laser interference patterning with a femtosecond Ti:Sapphire laser was employed, and two periodic grooved patterns were produced with a periodicity of 3 and 10 μm. A platform containing the cell-adhesive RGD and the osteogenic DWIVA peptides was used to functionalize the grooved surfaces. Topography and surface damage were characterized by confocal laser scanning (CLSM), scanning electron and scanning transmission electron microscopy techniques. The surface patterns exhibited a high homogeneity and subsurface damage was found in the form of nano-cracks and nano-pores, at the bottom of the valleys. Accelerated tests in water steam were carried out to assess hydrothermal degradation resistance, which slightly decreased after the laser treatment. Interestingly, the detrimental effects of the laser modification were reverted by a post-laser thermal treatment. The attachment of the molecule was verified trough fluorescence CLSM and X-ray photoelectron spectroscopy. Finally, the biological properties of the surfaces were studied in human mesenchymal stem cells. Cell adhesion, morphology, migration and differentiation were investigated. Cells on grooved surfaces displayed an elongated morphology and aligned along the patterns. On these surfaces, migration was greatly enhanced along the grooves, but also highly restricted in the perpendicular direction as compared to flat specimens. After biofunctionalization, cell number and cell area increased and well-developed cell cytoskeletons were observed. However, no effects on cell migration were found for the peptidic platform. Although some osteogenic potential was found in specimens grooved with a periodicity of 10 μm, the largest effects were observed from the biomolecule, which favored upregulation of several genes related to osteoblastic differentiation in all the surfaces.

Initial adhesion suppression of biofilm-forming and copper-tolerant bacterium Variovorax sp. on laser microtextured copper surfaces

The growth of detrimental biofilms on metal surfaces affects their structural performance and lifespan. Microtopographic texturization has emerged as an approach to suppress biofilm growth by preventing the initial stages of bacterial adhesion. This work studies the effects of linear pattern copper texturization on the initial adhesion steps of the biofilm-forming and copper-resistant bacterium Variovorax sp. Linear patterns with 4.7, 6.8, 14, and 18 μm periodicity were produced by direct laser interference patterning (DLIP) on copper coupons. Surface features were characterized by microscopic and spectroscopic techniques, and bacterial adhesion behavior was characterized by epifluorescence microscopy and functionalization of atomic force microscopy tips. We found a periodicity of 4.7 μm as the most efficient pattern to suppress Variovorax sp. initial adhesion by 31.1 % with respect to the nontextured surface. Preferential settlement in hummocks over hollows was observed for patterns with 14 and 18 μm periodicity, with adhesion events showing higher frequency in these topographies than patterns with periodicities of 4.7 and 6.8 μm. Our results highlight an understanding of the initial bacteria-copper adhesion and settlement behavior, thus contributing to the potential development of innocuous strategies for controlling biofilm growth on copper-based materials.

Aspect ratio of nano/microstructures determines Staphylococcus aureus adhesion on PET and titanium surfaces

AIMS

Joint infections cause premature implant failure. The avoidance of bacterial colonization of implant materials by modification of the material surface is therefore the focus of current research. In this in vitro study the complex interaction of periodic structures on PET and titanium surfaces on the adhesion of Staphylococcus aureus is analysed.

METHODS AND RESULTS

Using direct laser interference patterning as well as roll-to-roll hot embossing methods, structured periodic textures of different spatial distance were produced on surfaces and S. aureus were cultured for 24 h on these. The amount of adhering bacteria was quantified using fluorescence microscopy and the local adhesion behaviour was investigated using scanning electron microscopy. For PET structures, minimal bacterial adhesion was identified for an aspect ratio of about 0·02. On titanium structures, S. aureus adhesion was significantly decreased for profile heights of < 200 nm. Our results show a significantly decreased bacterial adhesion for structures with an aspect ratio range of 0·02 to 0·05.

CONCLUSIONS

We show that structuring on surfaces can decrease the amount of S. aureus on titanium and PET as common implant materials.

SIGNIFICANCE AND IMPACT OF THE STUDY

The study highlights the immense potential of applying specific structures to implant materials to prevent implant colonization with pathogen bacteria.

Laser Surface Texturing for Biomedical Applications: A Review

For generating a texture or pattern on a work surface, one of the emerging processes is laser surface texturing (LST). It is an effective method for producing texture on a work surface. Literature shows that various lasers have been applied to generate textures on the surface of work materials. Recently, LST has shown tremendous potential in the field of biomedical applications. Applying the LST process, the efficacy of the biomaterial has been drastically improved. This paper presents an in-depth review of laser surface texturing for biomedical applications. The effect of LST on important biomaterial has been thoroughly studied; it was found that LST has extreme potential for surface modification of biomaterial and can be utilized for biomedical applications.

Prediction of Optimum Process Parameters Fabricated by Direct Laser Interference Patterning Based on Central Composite Design

In this study, we report on the optimization of the direct laser interference patterning process by applying the design of experiments approach. The periodic line-like microstructures of a 8.50 µm spatial period were fabricated by a two-beam interference setup with nanosecond laser pulses, varying laser fluence, pulse overlap, and hatch distance. Central composite design with three factors and five levels was implemented to optimize the required number of experiments. The experimental and numerical results show the impact of various structuring process parameters on surface uniformity. The responses measured are the structure height, height error, and waviness of the pattern. An analysis of the microstructures on the patterned surface was conducted by confocal microscopy and scanning electron microscopy. A 3D-characterization method based on morphological filtering, which allows a holistic view of the surface properties, was applied, and a new qualification scheme for surface microstructures was introduced. Empirical models were also developed and validated for establishing relationships between process parameters and performance criteria. Multi-objective optimization was performed to achieve a minimal value of structure height errors and waviness.

Applying Ultrashort Pulsed Direct Laser Interference Patterning for Functional Surfaces

Surface structures in the micro- and nanometre length scale exert a major influence on performance and functionality for many specialized applications in surface engineering. However, they are often limited to certain pattern scales and materials, depending on which processing technique is used. Likewise, the morphology of the topography is in complex relation to the utilized processing methodology. In this study, the generation of hierarchical surface structures in the micro- as well as the sub-micrometre scale was achieved on ceramic, polymer and metallic materials by utilizing Ultrashort Pulsed Direct Laser Interference Patterning (USP-DLIP). The morphologies of the generated patterns where examined in relation to the unique physical interaction of each material with ultrashort pulsed laser irradiation. In this context, the pattern formation on copper, CuZn37 brass and AISI 304 stainless steel was investigated in detail by means of a combination of experiment and simulation to understand the individual thermal interactions involved in USP-DLIP processing. Thereby, the pattern's hierarchical topography could be tailored besides achieving higher process control in the production of patterns in the sub-µm range by USP-DLIP.

Development of an Analytical Model for Optimization of Direct Laser Interference Patterning

Direct laser interference patterning (DLIP) has proven to be a fast and, at the same time, high-resolution process for the fabrication of large-area surface structures. In order to provide structures with adequate quality and defined morphology at the fastest possible fabrication speed, the processing parameters have to be carefully selected. In this work, an analytical model was developed and verified by experimental data, which allows calculating the morphological properties of periodic structures as a function of most relevant laser-processing parameters. The developed model permits to improve the process throughput by optimizing the laser spot diameter, as well as pulse energy, and repetition rate. The model was developed for the structures formed by a single scan of the beam in one direction. To validate the model, microstructures with a 5.5 µm spatial period were fabricated on stainless steel by means of picosecond DLIP (10 ps), using a laser source operating at a 1064 nm wavelength. The results showed a difference of only 10% compared to the experimental results.

Development of a Monitoring Strategy for Laser-Textured Metallic Surfaces Using a Diffractive Approach

The current status of research around the world concurs on the powerful influence of micro- and nano-textured surfaces in terms of surface functionalization. In order to characterize the manufactured topographical morphology with regard to the surface quality or homogeneity, major efforts are still required. In this work, an optical approach for the indirect evaluation of the quality and morphology of surface structures manufactured with Direct Laser Interference Patterning (DLIP) is presented. For testing the designed optical configuration, line-like surface patterns are fabricated at a 1064 nm wavelength on stainless steel with a repetitive distance of 4.9 µm, utilizing a two-beam DLIP configuration. Depending on the pulse to pulse overlap and hatch distance, different single and complex pattern geometries are produced, presenting non-homogenous and homogenous surface patterns. The developed optical system permitted the successfully classification of different pattern geometries, in particular, those showing single-scale morphology (high homogeneity). Additionally, the fabricated structures were measured using confocal microscopy method, and the obtained topographies were correlated with the recorded optical images.

Picosecond Laser Interference Patterning of Periodical Micro-Architectures on Metallic Molds for Hot Embossing

In this work, it is demonstrated that direct laser interference patterning (DLIP) is a method capable of producing microtextured metallic molds for hot embossing processes. Three different metals (Cr, Ni, and Cu), relevant for the mold production used in nanoimprinting systems, are patterned by DLIP using a picosecond laser source emitting at a 532 nm wavelength. The results show that the quality and surface topography of the produced hole-like micropatterns are determined by the laser processing parameters, such as irradiated energy density and the number of pulses. Laser-induced periodic surface structures (LIPSS) are also observed on the treated surfaces, whose shapes, periodicities, and orientations are strongly dependent on the accumulated fluence. Finally, the three structured metals are used as embossing molds to imprint microlenses on polymethyl methacrylate (PMMA) foils using an electrohydraulic press. Topographical profiles demonstrate that the obtained structures are comparable to the masters showing a satisfactory reproduction of the texture. The polymeric microlens arrays that showed the best surface homogeneity and overall quality were those embossed with the Cr molds.

Bacterial Adhesion on Femtosecond Laser-Modified Polyethylene

In this study, femtosecond laser-induced sub-micrometer structures are generated to modify polyethylene (PE) surface topographies. These surfaces were subjected to bacterial colonization studies with Escherichia coli and Staphylococcus aureus as test strains. The results reveal that the nanostructures do not influence S. aureus coverage, while the adhesion of E. coli is reduced.

The Role of the Surface Nano-Roughness on the Wettability Performance of Microstructured Metallic Surface Using Direct Laser Interference Patterning

Superhydrophobic natural surfaces usually have multiple levels of structure hierarchy, particularly microstructures covered with nano-roughness. The multi-scale nature of such a surface reduces the wetting of water and oils, and supports self-cleaning properties. In this work, in order to broaden our understanding of the wetting properties of technical surfaces, biomimetic surface patterns were fabricated on stainless steel with single and multi-scale periodic structures using direct laser interference patterning (DLIP). Micropillars with a spatial period of 5.5 µm and a structural depth of 4.2 µm were fabricated and covered by a sub-micro roughness by using ultrashort laser pulses, thus obtaining a hierarchical geometry. In order to distinguish the influence of the different features on the wettability behavior, a nanosecond laser source was used to melt the nano-roughness, and thus to obtain single-scale patterns. Then, a systematic comparison between the single- and multi-scale structures was performed. Although, the treated surfaces showed hydrophilic behavior directly after the laser treatment, over time they reached a steady-state hydrophobic condition. However, the multi-scale structured metal showed a contact angle 31° higher than the single-scale geometry when the steady-state conditions were reached. Furthermore, the impact of the surface chemistry was investigated by energy dispersive X-ray spectroscopy (EDX) and X-ray photoelectron spectroscopy (XPS) analyses. Finally, a hydrophobizing agent was applied to the laser treated samples in order to further enhance the water contact angles and to determine the pure contribution of the surface topography. In the latter case, the multi-scale periodic microstructures reached static contact angles of 152° ± 2° and a contact angle hysteresis of only 4° ± 2°, while the single-scale structures did not show superhydrophobic behavior. These results definitely suggest that multi-scale DLIP structures in conjunction with a surface chemistry modification can promote a superhydrophobic regime.

Fabrication of inclined non-symmetrical periodic micro-structures using Direct Laser Interference Patterning

The direct fabrication of microstructures, having a non-symmetrical morphology with controllable inclination, presents nowadays a challenging task. Natural examples of surfaces with inclined topographies have shown to provide anisotropic functionalities, which have attracted the interest of several researchers in the last years. This work presents a microfabrication technique for producing microstructures with a determined and controllable inclination angle using two-beam Direct Laser Interference Patterning. Polyimide foils are irradiated with a 4 ns UV (266 nm) laser source producing line-like structures with a period varying from 4.6 µm to 16.5 µm. The inclinations, retrieved by tilting the sample with respect to the optical axis of the setup, are changed from 0° to 75°, introducing a well controllable and defined inclination of the structure walls. The structuring parameters (laser fluence, number of laser pulses and interference period) as well as the inclination of the microstructures are correlated with the global tilting of the sample. As a result, a determined laser fluence and number of pulses are necessary to observe a remarkable non-symmetrical morphology of the structures. In addition, the presence of structural undercuts is reported, which opens the possibility for developing new direction-dependent properties on polymeric materials. As an example, preliminary results on light diffraction are presented, showing a similar behavior as blazed diffraction gratings.

Biomimetic Surface Structuring Using Laser Based Interferometric Methods

This review investigates the capabilities of laser-based interferometric methods for producing structures with multiple-scaled surface features imitating natural examples. Firstly, laser interference lithography is used to produce hierarchical patterns with length-scales in the micrometer and sub-micrometer range. Different strategies are discussed to produce a wide variety of periodic arrays, depending on the number of resist lasers used as well as the way in which the exposure steps are organized. After that, periodic patterns are fabricated on polymers using ns laser pulses from an UV-laser system. Additionally in this case, multiple-scale patterns are produced by using different strategies. A similar approach is described to treat metallic surfaces of steel X6Cr17 and a titanium alloy Ti6Al4V. The geometry of the produced microstructures was characterized using scanning electron microscopy and confocal microscopy. Measurement of water contact angle is performed for both polymer and metallic surfaces.

Deposition of Ultrathin Nano-Hydroxyapatite Films on Laser Micro-Textured Titanium Surfaces to Prepare a Multiscale Surface Topography for Improved Surface Wettability/Energy

The primary aim of this study was to analyse the correlation between topographical features and chemical composition with the changes in wettability and the surface free energy of microstructured titanium (Ti) surfaces. Periodic microscale structures on the surface of Ti substrates were fabricated via direct laser interference patterning (DLIP). Radio-frequency magnetron sputter deposition of ultrathin nanostructured hydroxyapatite (HA) films was used to form an additional nanoscale grain morphology on the microscale-structured Ti surfaces to generate multiscale surface structures. The surface characteristics were evaluated using atomic force microscopy and contact angle and surface free energy measurements. The structure and phase composition of the HA films were investigated using X-ray diffraction. The HA-coated periodic microscale structured Ti substrates exhibited a significantly lower water contact angle and a larger surface free energy compared with the uncoated Ti substrates. Control over the wettability and surface free energy was achieved using Ti substrates structured via the DLIP technique followed by the deposition of a nanostructured HA coating, which resulted in the changes in surface chemistry and the formation of multiscale surface topography on the nano- and microscale.