Direct Laser Research Articles

Directional Laser Probe with Alcon/Lumenis Connector

Directional Laser Probe with Alcon/Lumenis Connector

Combination of MSC Marc and SE-FIT to simulate the direct laser deposition of the multi-layer Ti–6Al–4V

Modeling the impact of a laser heat source on Ti6Al4V deposition is crucial for optimizing additive manufacturing, particularly in multi-layer contexts. This modeling provides insights into the material’s behavior during the Ti6Al4V manufacturing process. In this study, simulations using MSC Marc were conducted to model the impact of a laser heat source on the deposition of the multi-layer Ti–6Al–4V (abbreviated as Ti6Al4V) using the Ti–6Al–4V metal powder, followed by SE-FIT simulation to characterize their deposition morphology. MSC Marc was utilized to simulate the impact of a laser heat source on the Ti6Al4V, with a focus on identifying the melting area. Thermal conductivity was represented in the form of a chart as a function of temperature. Next, the morphology after deposition was defined using SE-FIT based on volume and boundaries. In the MSC Marc numerical model, a combined heat transfer coefficient of radiation and convection was applied to the convective coefficient. In the section depicting the multi-layered deposition morphology, a laser with 750[Formula: see text]W power was utilized at a speed of 3.3[Formula: see text]mm/s. After simulation, the resulting layer height and appearance were compared with the literature for a 25-layer composite. The practical implications of this research extend to the broader field of laser-induced heat deposition on Ti6Al4V deposition, which has applications beyond titanium alloys. The findings may contribute to advancements in the design and manufacturing of various metal components, impacting industries such as automotive, electronics and energy.

Laser Patterning of Porous Support Membranes to Enhance the Effective Surface Area of Thin-Film Composite-Facilitated Transport Membranes for CO2 Separation.

Although thin-film composite membranes have achieved great success in CO2 separation, further improvements in the CO2 permeance are required to reduce the size and cost of the CO2 separation process. Herein, we report the fabrication of composite membranes with high CO2 permeability using a laser-patterned porous membrane as the support membrane. High-aspect-ratio micropatterns with well-defined micropores on their surface were carved on microporous polymer supports by a direct laser writing process using a short-pulsed laser. By using a Galvano scanner and optimizing the laser conditions and target materials, in-plane micropatterns, such as microhole arrays, microline grating, microlattices, and out-of-plane hierarchical micropatterns, were created on porous membranes. An aqueous suspension of hydrogel microparticles doped with an amine-based mobile carrier was sprayed onto the patterned surface to form a defect-free thin separation layer. The surface area of the separation layer on the patterned support is up to 80% larger than that of flat pristine membranes, resulting in a 52% higher CO2 permeance (1106 GPU) with a CO2/N2 selectivity of 172. The laser-patterned porous membranes allow the development of inexpensive and high-performance functional membranes not only for CO2 separation but also for other applications, such as water treatment, cell culture, micro-TAS, and membrane reactors.

NiCrBSi/WC Composite Claddings Processed on AISI 316L Steel Alloy by the Direct Laser Deposition Process: Studies on Dry Sliding Wear Behavior and Wear Mechanism Maps

Abstract This study presented the wear behavior of the NiCrBSi/WC composite claddings processed on an AISI 316L steel alloy substrate by laser cladding approach. The scanning electron microscope (SEM) morphology of the claddings has shown excellent substrate–cladding interface bonding, good WC particulate distribution, and no noticeable cracks and voids. The electron dispersion spectroscope (EDS) spectra have confirmed the presence of respective NiCrBSi alloy matrix and WC elements. The XRD spectra have identified various phases and compounds such as gamma-Ni, FeNi3, Ni3B, Cr23C6, Ni3Si, and W2C commonly in all the processed composite claddings. The microhardness of the claddings was measured between 791 and 1086 HV0.2 for increasing the reinforcement WC particulate percentage from 15 wt% to 60 wt%. It is about 470% surface hardness enhancement with the processed composite claddings compared with the substrate alloy. The reinforcement of WC from 15 wt% to 60 wt% with the composite claddings resulted in wear resistance enhancement from 21.85% to 60.64% and the coefficient of friction from 56.87% to 77.92% against the substrate. The wear-rate maps and their respective cladding's worn surface morphology have described the wear mechanisms typically as adhesive, abrasive, oxidation, and delamination. The wear mechanisms are mainly influenced by the WC particulate percentage. The increased WC particulate content has increased the dominance of the abrasive wear mechanism while reducing the window of the adhesive wear mechanism. The windows of various wear mechanisms and their ranges, such as adhesive 0.0033 to 0.028, abrasion 0.010 to 0.067, oxidation 0.012 to 0.093, and delamination 0.015 to 0.120 mm3/m, for NiCrBSi/WC composite claddings comprehensibly represented the wear behavior for the varied conditions of dry sliding wear parameters.

Commercial-Grade Dielectrics Surface Metallization by Direct Laser Deposition from Deep Eutectic Solvents

Commercial-Grade Dielectrics Surface Metallization by Direct Laser Deposition from Deep Eutectic Solvents

Fabrication of Gradient Periodic Surface Structures on Stainless Steel Using Direct Laser Interference Patterning

In this work, the fabrication of gradient periodic line‐like structures with continuously changing spatial period on stainless steel by means of two‐beam direct laser interference patterning (DLIP) is studied. A 70 ps (picosecond [ps]) pulsed laser operating at 532 nm wavelength and 0.64 J cm−2 laser fluence is used to produce the gradient microstructures. By continuously changing the overlapping angle between the sub‐beams, the spatial period of gradient structures smoothly increases from 2.01 ± 0.09 to 3.99 ± 0.12 μm within a 500 μm long processed area. Different pulse‐to‐pulse overlaps are applied to study the influence of cumulated fluence on the topography of gradient structures. The surface topography is analyzed by optical confocal microscopy and is characterized by the roughness parameters Ra and Rz. Fourier transformations of the confocal images allows the verification of the variations of the spatial periods. In the experiments performed in this work, design rules are provided for fabricating complex microstructures in the future using DLIP‐based technology to achieve advanced surface function like anisotropic wetting or cell growth.

Laser-Printed Photoanode: Femtosecond Laser-Induced Crystalline Phase Transformation of WO3 Nanorods for Space-Efficient and Flexible Thin-Film Solar Water-Splitting Cells.

Despite its potential for clean hydrogen harvesting, photoelectrochemical (PEC) water-splitting cells face challenges in commercialization, particularly related its harvesting performance and productivity at an industrial scale. Herein, a facile fabrication method of flexible thin-film photoanode for PEC water-splitting to overcome these limitations, based on laser processing technologies, is proposed. Laser-induced graphene, a carbon structure produced through direct laser writing carbonization (DLWC), plays a dual role: a flexible and stable current collector and a substrate for the hydrothermal synthesis of tungsten trioxide (WO3) nanorods (NRs). To facilitate water-splitting, a femtosecond-pulsed laser (fs laser) is focused on the WO3 NRs, converting their crystalline phase from pristine orthorhombic to monoclinic structure without thermal damage. With NiFe layered double hydroxide (LDH) catalyst, the flexible thin-film photoanode exhibits good PEC performance (1.46mAcm-2 at 1.23 VRHE) and retains ≈90% of its performance after 3000 bending cycles. With its excellent mechanical properties, the flexible photoanode can be operated in various shapes with different curvatures, enabling space-efficient PEC water-splitting by loading larger photoanode within a given space. This study is expected to contribute to the advancement of large-scale solar water-splitting cells, introducing a new approach to enhance H2/O2 production and expand its application range.

Direct laser patterning of glass mask for micro display using GHz bursts

AbstractDevelopment of high‐precision RGB patterning process is needed to implement high‐resolution micro display (OLEDoS) for next‐generation VR/AR products. In general, specially designed and manufactured masks are required to realize above 3000‐ppi high‐resolution display in structured OLED material deposition. In this study, we developed direct laser patterning IR‐fs optical system operating in MHz and GHz burst modes and evaluated its capability for precise micro‐drilling of aluminoborosilicate glass materials. The fine hole‐shaped pattern is produced at a minimum of 5 μm pitch level for about 0.6 in. area without sacrificing the glass strength. It is expected to contribute to the high precise manufacture of ultra fine mask (UFM) using thin glass platform corresponding to micro displays in the future.

Enhanced Thin‐Film Encapsulation Through Micron‐Scale Anchors

AbstractImplantable medical devices require protective encapsulation to isolate them from the biological environment. Parylene‐C (PaC) is a prevalent encapsulation polymer but is susceptible to cracking, delamination, oxidation, and moisture penetration over time. This study demonstrates that 3D micro‐anchors fabricated by direct laser writing (DLW) greatly enhance PaC lifetime and encapsulation properties. The PaC film is vapor deposited onto these anchor points, followed by ultraviolet radiation (UV)‐curing‐induced shrinkage. Electrochemical impedance spectroscopy (EIS) during accelerated aging tests in reactive solutions (87 °C, 15 mM H2O2) is performed to monitor film degradation over time. Unpatterned PaC films failed before reaching the 3.25 accelerated year benchmark, while 100 µm spaced micro‐anchors extended encapsulation up to 5.5 equivalent years. Subsequent improvements are achieved with a spacing of 50 µm, demonstrating viability up to ≈6 equivalent years. This research demonstrates the benefit of engineering anchor points for preventing delamination of the PaC layer and significantly enhancing encapsulation properties. Printed 3D micro‐anchors are an extremely flexible platform, with many different shapes and sizes possible which can further enhance longevity. The success in increasing coating lifetimes offers a promising direction for improving long‐term implantable medical devices, potentially revolutionizing their longevity and reliability.

Diffusion properties of silk-derived laser-induced graphene

Direct laser writing is an efficient method for producing graphene on a substrate. This study investigated the formation of laser-induced graphene on silk fibers using molecular dynamics simulation and ReaxFF. The use of natural substrates such as silk fibers in laser-induced graphene has significant advantages in the industry due to their biodegradability and recyclability, making silk a preferred component in biomaterials and wearable biosensors. The study also looked into the diffusion coefficient of silk-derived laser-induced graphene using the MSD method and ReaxFF approach at varying temperatures and lengths. The simulation results showed that there is a non-linear relationship between the diffusion coefficient and temperature, while a linear relationship exists between the diffusion coefficient and graphene size. Interestingly, larger graphene structures exhibited a lower diffusion coefficient.

Development of Micro/Nano Pattern Arrays with Grating-Based Periodic Structures using the Direct Laser Lithography System

Introduction: This research delves into utilizing the Direct Laser Lithography System to produce micro/nanopattern arrays with grating-based periodic structures. Initially, refining the variation in periodic structures within these arrays becomes a pivotal pursuit. This demands a deep comprehension of how structural variation aligns with specific applications, particularly in photonics and material science. Method: Advancements in hardware, software, or process optimization techniques hold potential for reaching this objective. Using an optical beam, this system enables the engraving of moderate periodic and quasi-periodic structures, enhancing pattern formation in a three-dimensional environment. Through cost-effective direct-beam interferometry systems utilizing 405 nm GaN and 290 to 780 nm AlInGaN semiconductor laser diodes, patterns ranging from in period were created, employing 300 nm gratings. Result: The system's cost-efficiency and ability to achieve high-resolution permit the creation of both regular and irregular grating designs. By employing an optical head assembly from a bluray disc recorder, housing a semiconductor laser diode and an objective lens with an NA of 0.85, this system displays promising potential in progressing the fabrication of micro/nanopattern arrays. Conclusion: Assessing their optical, mechanical, and electrical properties and exploring potential applications across varied fields like optoelectronics, photovoltaics, sensors, and biomedical devices represent critical strides for further exploration and advancement.

Comparative analysis of modern technologies of additive production

In today's conditions, 3D printing is used to create unique models, prototypes, and equipment necessary for conducting experiments and studying various phenomena and processes, for the rapid prototyping of various parts and devices in scientific and engineering research. 3D printing technologies are actively used to create individual medical implants, prostheses, and organ models for training and planning operations, which significantly improves the quality of medical care. In the aerospace and automotive industries, additive manufacturing is used to create lightweight and durable parts helping to reduce weight and improve vehicle efficiency. The use of additive manufacturing methods, technologies, and tools allows you to check and test designs and concepts before mass production. In this work, a detailed analysis of various existing 3D printers is carried out depending on the tasks, and modern technologies of additive manufacturing are investigated depending on the set goals and scientific and applied tasks. Such technologies include Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, and Digital Light Processing. In the work, a comparative analysis of these technologies was carried out according to various criteria, such as principle of operation, materials, resolution, surface finish, accuracy, speed, strength, application, cost, complexity of parts, and post-processing. For each technology, the advantages and disadvantages of its use are determined depending on the goals and objectives. It should be noted that some materials may not be suitable for printing complex parts or require additional support during the printing process. This can lead to complexity in the processing of products and increase the time and costs of printing. Improper selection of materials for 3D printing can be harmful to the environment or human health when used incorrectly. For example, some plastic materials may emit toxic elements or have low biodegradability. Also, using excess expensive material unnecessarily can increase the cost of the project. Keywords: additive manufacturing, 3D printing, additive manufacturing technologies, Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, Digital Light Processing.

Structured polarized laser beams for controlled spiral-shaped mass transfer in azopolymer thin films

We present an approach for the realization of controlled spiral-shaped mass transfer in azopolymer thin films and the fabrication of spiral microreliefs. For such laser processing, we propose to use light fields with structured polarization distributions generated by a transmissive spatial light modulator. The projection lithography approach is utilized, transferring the pattern directly to the surface of azopolymer thin films. The shaped polarization distributions with different dependencies of the polarization vector orientation on the azimuthal angle allow us to drive surface waves on the sample along a spiral trajectory. Additionally, the ability to control the concavity of the formed microreliefs is demonstrated. This approach can be effectively modified for the direct laser fabrication of more complex nano-/micro-elements as well as their arrays.

Development of a facile, versatile and scalable fabrication approach of solid, coated, and dissolving microneedle devices for transdermal drug delivery applications

Nowadays, microneedles as novel transdermal delivery systems are interested in scientists for biomedical applications. This work aims to present a Cascade Microneedle Molding Technique (CMMT) for the reusable fabrication of polydimethylsiloxane (PDMS) molds to produce microneedle devices. To produce a positive master mold from epoxy resin, a negative PDMS mold was first fabricated. PDMS can be molded, and microneedles can be fabricated using this epoxy mold in a scalable and cost-effective manner. These molds were used to manufacture solid, coated, and dissolving microneedles, which were characterized comprehensively. Microneedle morphology and geometry were evaluated using Scanning Electron Microscopy (SEM). The mechanical integrity and ability to insert the microneedle device into the skin were assessed using compression strength analysis and force-displacement measurements. Drug penetration through animal skin was evaluated for Rhodamine B (RhB) loaded microneedles. The depth of needle insertion was also visualized using histological analysis while the spatial distribution of released cargo was determined by using confocal microscopy. Taken together, CMMT offers a simple, rapid, cost-effective, and scalable method for mass-producing microneedles with remarkable properties compared to direct 3D printing or laser ablation.

Combinatorial Benders decomposition for single machine scheduling in additive manufacturing with two-dimensional packing constraints

This paper addresses a single-machine scheduling problem in additive manufacturing (AM). We focus on the direct metal laser sintering (DMLS) technology of an AM process, where parts can be produced simultaneously in a batch. In this problem, we consider simultaneously the assignment of parts to batches and the packing of parts onto two-dimensional surfaces of the build chamber to minimize the makespan objective. To solve this problem, a mixed integer linear programming model is formulated, and an approximation algorithm is proposed, followed by an exact algorithm based on combinatorial Benders decomposition method with various Benders cuts and acceleration strategies (Algorithm CBD). Finally, we conduct a comprehensive computational study to verify the efficiency of our proposed Algorithm CBD. The computational results show that our proposed Algorithm CBD can effectively solve the test instances with different sizes.

Influence of chemistry and topography on the wettability of copper

To understand the complex interplay of topography and surface chemistry in wetting, fundamental studies investigating both parameters are needed. Due to the sensitivity of wetting to miniscule changes in one of the parameters it is imperative to precisely control the experimental approach. A profound understanding of their influence on wetting facilitates a tailored design of surfaces with unique functionality.We present a multi-step study: The influence of surface chemistry is analyzed by determining the adsorption of volatile carbonous species (A) and by sputter deposition of metallic copper and copper oxides on flat copper substrates (B). A precise surface topography is created by laser processing. Isotropic topography is created by ps laser processing (C), and hierarchical anisotropic line patterns are produced by direct laser interference patterning (DLIP) with different pulse durations (D).Our results reveal that the long-term wetting response of polished copper surfaces stabilizes with time despite ongoing accumulation of hydrocarbons and is dominated by this adsorption layer over the oxide state of the substrate (Cu, CuO, Cu2O). The surfaces’ wetting response can be precisely tuned by tailoring the topography via laser processing. The sub-pattern morphology of primary line-like patterns showed great impact on the static contact angle, wetting anisotropy, and water adhesion. An increased roughness inside the pattern valleys combined with a minor roughness on pattern peaks favors air-inclusions, isotropic hydrophobicity, and low water adhesion. Increasing depth of the primary topography can also induce air-inclusions despite increasing peak roughness while time dependent wetting transitions were observed.

Antibacterial property alterations induced by low zinc content in laser-structured brass

Brass, along with other copper-based alloys, exhibits advantageous antibacterial properties that can be further enhanced by altering the surface topography to increase bacterial adhesion. This enhancement is achievable through a higher contact area created by precise periodic structures, each approximately the size of a single bacterial cell. One method for generating these structures is ultrashort pulsed direct laser interference patterning (USP-DLIP). However, this process may induce chemical alterations in addition to topographical changes, depending on the substrate’s composition. To mitigate unfavorable chemical alterations, brass with a 15% zinc content was selected for this study. The antibacterial effectiveness of the modified surfaces was tested against Escherichia coli, providing initial insights into the interaction between bacteria and the substrate. The results indicate that modified brass with a 15% zinc content shows improved antibacterial activity. Overall, this research demonstrates that by modifying a surface with the appropriate chemical composition, effective bacterial elimination through contact can be achieved.

The influence of laser focusing conditions on the direct laser acceleration of electrons

Direct laser acceleration of electrons during a high-energy, picosecond laser interaction with an underdense plasma has been demonstrated to be substantially enhanced by controlling the laser focusing geometry. Experiments using the OMEGA EP facility measured electrons accelerated to maximum energies exceeding 120 times the ponderomotive energy under certain laser focusing, pulse energy, and plasma density conditions. Two-dimensional particle-in-cell simulations show that the laser focusing conditions alter the laser field evolution, channel fields generation, and electron oscillation, all of which contribute to the final electron energies. The optimal laser focusing condition occurs when the transverse oscillation amplitude of the accelerated electron in the channel fields matches the laser beam width, resulting in efficient energy gain. Through this observation, a simple model was developed to calculate the optimal laser focal spot size in more general conditions and is validated by experimental data.

Near-infrared laser induced direct ignition of 4,4′,5,5′-tetranitro-1H,1′H-[2,2′-biimidazole]-1,1′-diamine by constructing diverse crystal structures

Although laser ignition is considered to be one of the most promising ways to detonate energetic materials due to its high safety and reliability, it is still a challenge to achieve direct ignition of energetic materials by a laser with low-power and near-infrared (NIR) band. In this paper, a molecular self-assembly strategy based on recrystallization was utilized to prepare 4,4′,5,5′-tetranitro-1H,1′H-[2,2′-biimidazole]-1,1′-diamine (DATNBI) crystals with various micro-nano structures. The characterization results suggest that DATNBI crystals with different degrees of roughness and defects by the induction of solvents and surfactants. The crystal defects can not only bring about the enhancement of light absorption of DATNBI in NIR band, but also advance its thermal decomposition, providing reliable support for direct laser ignition of DATNBI profit from the hot spot ignition theory. Combined with density functional theory, it is speculated that electrons of defect states achieve electron-hole recombination by laser radiation, thereby enhancing photothermal conversion. Compared with raw DATNBI, DATNBI crystals with rough surface and abundant defects can be directly ignited by a NIR laser and exhibits self-sustainable combustion. In summary, a direct NIR laser-ignitable energetic material has been prepared via appropriate crystal structure design.

Toward Synthetic Physical Fingerprint Targets.

Biometric fingerprint identification hinges on the reliability of its sensors; however, calibrating and standardizing these sensors poses significant challenges, particularly in regards to repeatability and data diversity. To tackle these issues, we propose methodologies for fabricating synthetic 3D fingerprint targets, or phantoms, that closely emulate real human fingerprints. These phantoms enable the precise evaluation and validation of fingerprint sensors under controlled and repeatable conditions. Our research employs laser engraving, 3D printing, and CNC machining techniques, utilizing different materials. We assess the phantoms' fidelity to synthetic fingerprint patterns, intra-class variability, and interoperability across different manufacturing methods. The findings demonstrate that a combination of laser engraving or CNC machining with silicone casting produces finger-like phantoms with high accuracy and consistency for rolled fingerprint recordings. For slap recordings, direct laser engraving of flat silicone targets excels, and in the contactless fingerprint sensor setting, 3D printing and silicone filling provide the most favorable attributes. Our work enables a comprehensive, method-independent comparison of various fabrication methodologies, offering a unique perspective on the strengths and weaknesses of each approach. This facilitates a broader understanding of fingerprint recognition system validation and performance assessment.