Non-Diffractive Bessel Beams for Ultrafast Laser Scanning Platform and Proof-Of-Concept Side-Wall Polishing of Additively Manufactured Parts

Laser-Based Selective Material Processing for Next-Generation Additive Manufacturing

The connection between laser-based material processing and additive manufacturing is quite deeply rooted. In fact, the spark that started the field of additive manufacturing is the idea that two intersecting laser beams can selectively solidify a vat of resin. Ever since, laser has been accompanying the field of additive manufacturing, with its repertoire expanded from processing only photopolymer resin to virtually any material, allowing liberating customizability. As a result, additive manufacturing is expected to take an even more prominent role in the global supply chain in years to come. Herein, an overview of laser-based selective material processing is presented from various aspects: the physics of laser-material interactions, the materials currently used in additive manufacturing processes, the system configurations that enable laser-based additive manufacturing, and various functional applications of next-generation additive manufacturing. Additionally, current challenges and prospects of laser-based additive manufacturing are discussed.

Femtosecond Laser Direct Writing of Flexible Electronic Devices: A Mini Review

By virtue of its narrow pulse width and high peak power, the femtosecond pulsed laser can achieve high-precision material modification, material additive or subtractive, and other forms of processing. With additional good material adaptability and process compatibility, femtosecond laser-induced application has achieved significant progress in flexible electronics in recent years. These advancements in the femtosecond laser fabrication of flexible electronic devices are comprehensively summarized here. This review first briefly introduces the physical mechanism and characteristics of the femtosecond laser fabrication of various electronic microdevices. It then focuses on effective methods of improving processing efficiency, resolution, and size. It further highlights the typical progress of applications, including flexible energy storage devices, nanogenerators, flexible sensors, and detectors, etc. Finally, it discusses the development tendency of ultrashort pulse laser processing. This review should facilitate the precision manufacturing of flexible electronics using a femtosecond laser.

Ultrafast laser-induced plasma anisotropy in pristine and surface pre-structured zinc telluride, probed by terahertz pulses

We use THz probe pulses to detect and analyze the dynamics of charge transport anisotropies generated by ultrafast laser two-photon absorption in Zinc Telluride (ZnTe) semi-insulating crystal showing smooth and laser structured surfaces. The detected anisotropy consists in a modulation of the THz transmission as a function of the orientation of the <001 > axis of ZnTe. The change in THz transmission after pump excitation is attributed to free carrier absorption of the THz field in the laser-induced electron-hole plasma. Pre-structuring the surface sample with laser-induced periodic surface structures (ripples) has strong influence on free carrier THz transmission and its associated anisotropic oscillation. Within the relaxation dynamics of the laser-induced free carriers, two relaxation times have to be considered in order to correctly describe the dynamics, a fast relaxation, of about 50 picoseconds in pristine sample (90 picoseconds in sample pre-structured with ripples), and a slow one, of about 1.5 nanoseconds. A theoretical model based on classical Drude theory and on the dependence of the two-photon absorption coefficient with the crystal orientation and with the laser polarization is used to fit the experimental results.

Flat variable liquid crystal diffractive spiral axicon enabling perfect vortex beams generation

A transparent variable diffractive spiral axicon (DSA) based on a single LC cell is presented. The manufactured DSA can be switched between 24 different configurations, 12 convergent and 12 divergent, where the output angle is varied as a function of the applied topological charge. The active area of the device is created using a direct laser writing technique in indium-tin oxide coated glass substrates. Liquid crystal is used to modulate the phase of the incoming beam generating the different DSA configurations. The DSA consists in 24 individually driven transparent spiral shaped electrodes, each introducing a specific phase retardation. In this article, the manufacture and characterization of the tunable DSA is presented and the performance of the DSA is experimentally demonstrated and compared to the corresponding simulations.

A Review of Spatter in Laser Powder Bed Fusion Additive Manufacturing: In Situ Detection, Generation, Effects, and Countermeasures

Spatter is an inherent, unpreventable, and undesired phenomenon in laser powder bed fusion (L-PBF) additive manufacturing. Spatter behavior has an intrinsic correlation with the forming quality in L-PBF because it leads to metallurgical defects and the degradation of mechanical properties. This impact becomes more severe in the fabrication of large-sized parts during the multi-laser L-PBF process. Therefore, investigations of spatter generation and countermeasures have become more urgent. Although much research has provided insights into the melt pool, microstructure, and mechanical property, reviews of spatter in L-PBF are still limited. This work reviews the literature on the in situ detection, generation, effects, and countermeasures of spatter in L-PBF. It is expected to pave the way towards a novel generation of highly efficient and intelligent L-PBF systems.

Engineering a better light sheet in an axicon-based system using a flattened Gaussian beam of low order

Lasers are fundamental tools in research and development. The shape of an incident laser beam directly affects the results, when it propagates through complex structured meso-aspheric optical elements. In conic-based systems utilizing elements such as axicons, the impact of secondary lobes is mostly overlooked, although the intensity distributions at the central spot and the side-lobes directly affect the beam properties. We investigate the interaction of two axicons (160° and 170°) with incident beams approximated by Gaussian, high-order Flattened-Gaussian, and low-order Flattened-Gaussian functions. We demonstrate that replacing an incident Gaussian beam with a low-order Flattened-Gaussian beam reduces the secondary lobes and significantly improves the uniformity of the intensity profile. We practically applied this effect in engineering a conic-aspheric-based static light-sheet microscope producing markedly improved results.

Modern Types of Axicons: New Functions and Applications

Axicon is a versatile optical element for forming a zero-order Bessel beam, including high-power laser radiation schemes. Nevertheless, it has drawbacks such as the produced beam's parameters being dependent on a particular element, the output beam's intensity distribution being dependent on the quality of element manufacturing, and uneven axial intensity distribution. To address these issues, extensive research has been undertaken to develop nondiffracting beams using a variety of advanced techniques. We looked at four different and special approaches for creating nondiffracting beams in this article. Diffractive axicons, meta-axicons-flat optics, spatial light modulators, and photonic integrated circuit-based axicons are among these approaches. Lately, there has been noteworthy curiosity in reducing the thickness and weight of axicons by exploiting diffraction. Meta-axicons, which are ultrathin flat optical elements made up of metasurfaces built up of arrays of subwavelength optical antennas, are one way to address such needs. In addition, when compared to their traditional refractive and diffractive equivalents, meta-axicons have a number of distinguishing advantages, including aberration correction, active tunability, and semi-transparency. This paper is not intended to be a critique of any method. We have outlined the most recent advancements in this field and let readers determine which approach best meets their needs based on the ease of fabrication and utilization. Moreover, one section is devoted to applications of axicons utilized as sensors of optical properties of devices and elements as well as singular beams states and wavefront features.

Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing

High thermal gradients and complex melt pool instabilities involved in powder bed fusion–based metal additive manufacturing using focused Gaussian-shaped beams often lead to high porosity, poor morphological quality, and degraded mechanical performance. We show here that Bessel beams offer unprecedented control over the spatiotemporal evolution of the melt pool in stainless steel (SS 316L) in comparison to Gaussian beams. Notably, the nondiffractive nature of Bessel beams enables greater tolerance for focal plane positioning during 3D printing. We also demonstrate that Bessel beams significantly reduce the propensity for keyhole formation across a broad scan parameter space. High-speed imaging of the melt pool evolution and solidification dynamics reveals a unique mechanism where Bessel beams stabilize the melt pool turbulence and increase the time for melt pool solidification, owing to reduced thermal gradients. Consequently, we observe a distinctively improved combination of high density, reduced surface roughness, and robust tensile properties in 3D-printed test structures.