Scanning Strategies in Laser Surface Texturing: A Review

A feasibility study on femtosecond laser texturing of sprayed nanocellulose coatings

Nanocelluloses are emerging as natural materials with favourable properties for coating industry and can be applied by state-of-the-art spraying technology. While additional functionalities are commonly introduced through chemical modification, the surface microstructuring of nanocellulose coatings with high throughput methods remains unexplored. Here, a femtosecond laser is used for texturing spray-coated coatings made of cellulose nanofibrils (CNF) or cellulose nanocrystals (CNC). For coating thickness of 1.5 to 8 μm, processing limits were determined with maximum ablation energy linearly increasing with coating thickness and minimum ablation energy decreasing or increasing depending on the apparent coating density. Within applicable processing window of pulse rate and power setting, the operational ranges were determined for creating one-dimensional and two-dimensional surface patterns, requiring a higher laser energy for CNC compared to CNF coatings and yielding thinnest possible resolved patterns of 17 μm as determined by the laser spot diameter. The laser ablation under low energy corresponds to an increase in surface roughness and intensifies surface hydrophilicity, while the line patterns are able to pin water droplets with rising water contact angles up to 90°. Present feasibility study opens future possibilities for managing surface properties of nanocellulose coatings in applications where tuning of surface hydrophilicity is required.

Direct Laser Writing: From Materials Synthesis and Conversion to Electronic Device Processing

Direct Laser Writing (DLW) has been increasingly selected as a microfabrication route for efficient, cost-effective, high-resolution material synthesis and conversion. Concurrently, lasers participate in the patterning and assembly of functional geometries in several fields of application, of which electronics stand out. In this review, recent advances and strategies based on DLW for electronics microfabrication are surveyed and outlined, based on laser material growth strategies. First, the main DLW parameters influencing material synthesis and transformation mechanisms are summarized, aimed at selective, tailored writing of conductive and semiconducting materials. Additive and transformative DLW processing mechanisms are discussed, to open space to explore several categories of materials directly synthesized or transformed for electronics microfabrication. These include metallic conductors, metal oxides, transition metal chalcogenides and carbides, laser-induced graphene, and their mixtures. By accessing a wide range of material types, DLW-based electronic applications are explored, including processing components, energy harvesting and storage, sensing, and bioelectronics. The expanded capability of lasers to participate in multiple fabrication steps at different implementation levels, from material engineering to device processing, indicates their future applicability to next-generation electronics, where more accessible, green microfabrication approaches integrate lasers as comprehensive tools.

Wetting Behavior Driven by Surface Morphology Changes Induced by Picosecond Laser Texturing

The laser surface texturing (LST) technique has recently been used to enhance adhesion bond strength in various coating applications and to create structures with controlled hydrophobic or superhydrophobic surfaces. The texturing processing parameters can be adjusted to tune the surface's polarity, thereby controlling the ratio between the polar and dispersed components of the surface free energy and determining its hydrophobic character. The aim of this work is to systematically select appropriate laser and scan head parameters for high-quality surface topography of metal-based materials. A correlation between texturing parameters and wetting properties was made in view of several technological applications, i.e., for the proper growth of conformal layers onto laser-textured metal surfaces. Surface analyses, carried out by scanning electron microscopy and profilometry, reveal the presence of periodic microchannels decorated with laser-induced periodic surface structures (LIPSS) in the direction parallel to the microchannels. The water contact angle varies widely from about 20° to 100°, depending on the treated material (titanium, nickel, etc.). Nowadays, reducing the wettability transition time from hydrophilicity to hydrophobicity, while also changing environmental conditions, remains a challenge. Therefore, the characteristics of environmental dust and its influence on the properties of the picosecond laser-textured surface (e.g., chemical bonding of samples) have been studied while monitoring ambient conditions.

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.