Polishing Technique Research Articles

Microstructural evolution and mechanical properties of LDED Ti-6Al-4 V alloy polished with a hybrid laser polishing technique

Microstructural evolution and mechanical properties of LDED Ti-6Al-4 V alloy polished with a hybrid laser polishing technique

Generation of Mode-Locked Pulses Assisted by Reduced Graphene Oxide/Cerium Oxide (rGO/CeO2) Embedded in Arc-Shaped Fiber

Abstract This study demonstrates the synthesis of a reduced graphene oxide/cerium oxide (rGO/CeO2) composite and its successful use as a saturable absorber (SA) in ultrafast photonics. The rGO/CeO2 composite was synthesized using a facile hydrothermal approach, and an arc-shaped fiber was fabricated using a polishing technique. The arc-shaped fiber employed indirect evanescent field coupling, allowing interaction between the composite material and the laser, which facilitated the generation of mode-locked pulses. An arc-shaped fiber drop-casted with rGO/CeO2 was connected to a 2.0 µm laser source, achieving a modulation depth of 50.16%. The emitted laser pulses have a duration of 1.776 ps, an operational wavelength of 1904 nm, and a spectral bandwidth (FWHM) of 2.76 nm. The pulse energy was 89.36 pJ with a high signal-to-noise ratio (SNR) of 63 dB. This study introduces rGO/CeO2 embedded in an arc-shaped fiber as an effective SA, exhibiting favorable nonlinear optical absorption in the near 2.0 µm wavelength region, making it suitable for applications in ultrafast photonics.

Effect of finishing and polishing techniques on the fit accuracy and dimensions of conventional and CAD‐CAM removable partial denture frameworks

Effect of finishing and polishing techniques on the fit accuracy and dimensions of conventional and CAD‐CAM removable partial denture frameworks

Evaluation of Colour Changes in Nanocomposite-Based Bulk-Fill and Universal Composite Using Different Polishing Systems.

Resins composites are widely used in modern dentistry because of their aesthetic and physical properties. However, discoloration of anterior tooth restorations is a common complaint. Understanding the factors affecting the colour stability of resin composites can lead to longer-lasting repairs. This study aimed to evaluate and compare the colour changes of nanocomposite-based bulk-fill and universal resin composites after immersion in coffee using various polishing systems. A total of 160 samples were prepared using four different composite groups, with 40 pieces for each combined group. Based on the finishing procedure, the samples were divided into four subgroups for each composite group. Three different polishing procedures were applied to the samples according to the manufacturer's instructions. The control group was not subjected to any treatment. Initial colour measurements were performed using a VITA Easyshade V spectrophotometer. After the initial measurements, the samples were immersed in a Nescafe coffee solution for seven days, followed by colour measurements. Data were analysed using the Kolmogorov-Smirnov test and two-way analysis of variance. Tukey's honest significant difference (HSD) test was used to determine differences between subgroups. The results indicate that bulk-fill resins exhibit more discolouration than universal composites; however, this difference was not statistically significant. The resin group with the smallest discolouration was Ceram X, and the most effective polishing method was Twist polishing. Final surface polishing significantly reduced the composites' discolouration. These findings support the selection of appropriate materials and polishing techniques to achieve aesthetic outcomes and colour stability in dental restorations.

Comparative Evaluation of Biofilm Formation on Temporization Crown Materials Used in the Rehabilitation of Primary Dentition With Different Polishing Materials: An In Vitro Study.

Introduction Advancements in dental materials have enhanced aesthetic treatments for managing dental caries and injuries in primary dentition. Bis-acryl composite-based temporization materials are now preferred for restoring primary crowns due to their superior properties. However, prolonged exposure to dietary and hygienic factors can lead to discoloration and roughness, making efficient polishing essential to prevent plaque buildup. Objective This study aims to evaluate Streptococcus mutans biofilm formation on temporization material polished with different polishing systems. Methods This study tested bis-acryl methacrylate temporization material. Thirty disk-shaped specimens were prepared and divided into three groups according to the polishing system used (n = 10 per group): Shofu Super Snap mini kit (Shofu, San Marcos, CA), aluminum oxide polishing paste, and propol polishing paste. Each group's specimens were polished according to the manufacturer's instructions. Surface roughness (SR), scanning electron microscopy (SEM) morphological analysis, and Streptococcus mutans biofilm formation were assessed for each group. Results The results showed significant differences in roughness average (Ra) values among the polishing materials, with the Shofu Super Snap mini kit having the highest roughness (Ra = 2.04), followed by propol polishing paste (Ra = 1.30)and aluminum oxide paste (Ra = 0.75). Additionally, polishing methods significantly affected mean colony-forming unit (CFU) levels, with the first group having the highest mean CFU value (0.24), with SEM images showing substantial biofilm formation by Streptococcus mutans. Conclusion Bacterial biofilm formation on the aluminum oxide paste group's surface differed from that on the propol polishing paste and aluminum oxide disc groups. The polishing techniques that we tested significantly influenced surface properties and biofilm formation. These findings suggest that selecting an appropriate polishing system can reduce the risk of gingival inflammation associated with temporization materials.

Improved performance of three mirror anastigmat telescope with freeform surface: Optical design, testing and validation aspects

"In this paper, the optical design of a Three Mirror Anastigmat (TMA) Telescope is modified by substitution of a convex freeform secondary and optimization carried out to obtain improved performance. The proposed convex freeform surface is precisely manufactured using the bonnet polishing technique and tested with a sub-aperture stitched algorithm, meeting the specified surface accuracy requirements. Further, to validate the design, the realized secondary freeform optic is tested in conjunction with primary and tertiary optics in the conceived TMA configuration. The telescope system performance is established using a double-pass interferometric test setup. The modified design enhances the telescope system's performance in the extended field of view (FoV) from ±2.5° to ±3.5° across the track and from ±0.4° to ±0.6° along the track. Measured performance results demonstrate an average modulation transfer function (MTF) of 0.56 and an average Strehl ratio of 0.64 at all field points. The effective focal length of the system is computed to be 975 mm. In summary, the proposed freeform surface significantly improves the optical system performance within the available real estate of the envisaged space telescope system."

Enhancing Slurry Stability and Surface Flatness of Silicon Wafers through Organic Amine-Catalyzed Synthesis Silica Sol.

The stability of slurries used for chemical mechanical polishing (CMP) is a crucial concern in industrial chip production, influencing both the quality and cost-effectiveness of polishing fluids. In silicon wafer polishing, the conventional use of commercial neutral silica sol combined with organic bases often leads to slurry instability. To address this issue, this study proposes organic amines-specifically ethanolamine (MEA), ethylenediamine (EDA), and tetramethylammonium hydroxide (TMAOH)-as catalysts for synthesizing alkaline silica sol tailored for silicon wafer polishing fluids. Sol-gel experiments and zeta potential measurements demonstrate the efficacy of this approach in enhancing the stability of silica sol. The quantitative analysis of surface hydroxyl groups reveals a direct correlation between enhanced stability and increased hydroxyl content. The application of the alkaline silica sol in silicon wafer polishing fluids improves polishing rates and enhances surface flatness according to atomic force microscopy (AFM). In addition, electrochemical experiments validate the capability of this polishing solution to mitigate corrosion on silicon wafer surfaces. These findings hold significant implications for the advancement of chemical mechanical polishing techniques in the field of integrated circuit fabrication.

Occurrence, persistence, and removal of contaminants of emerging concern through drinking water treatment processes – A case study in South Africa

The presence of contaminants of emerging concern (CECs) in drinking water is a global issue of concern. Evidence galore of the potential impacts of CECs on human health, yet there are no concrete guidelines or regulatory oversight to effectively tackle CECs exposure from drinking water. As a result, CECs concentrations can be well-above the suggested thresholds, particularly in low and middle-income countries (LMICs) due to undeveloped or underdeveloped (waste)water treatment infrastructure and/or substandard treatment practices. Yet, CECs occurrence and particularly their persistence during drinking water treatment is not well-documented in such settings. For this reason, here, the occurrence of 19 CECs was monitored across the different treatment steps (coagulation, sedimentation, sand filtration, and chlorination) of a typical water treatment plant in South Africa using UPLC-MS/MS. The most dominant CEC was, by and large, efavirenz (1103.9 ± 743.1 ng/L in raw water) tracing back to antiretroviral treatment for the human immunodeficiency virus (HIV) and revealing unpleasant realities about the HIV epidemic crisis in Sub-Sahara Africa (Global South) and possible drug abuse for illicit drug (whoonga/nyaope) manufacturing. For the other examined CECs, their concentrations in drinking water were, from higher to lower score: 1,7 dimethylxanthine (403.3 ± 244.2 ng/L) ≥ emtricitabine (358.4 ± 250.8 ng/L) ≥ atrazine (227.0 ± 61.0 ng/L) ≥ caffeine (194.1 ± 216.5 ng/L) ≥ tramadol (189.5 ± 112.4 ng/L) ≥ carbamazepine (122.9 ± 24.5 ng/L) ≥ sulfamethoxazole (107.8 ± 55.1 ng/L) ≥ methaqualone (72.2 ± 20.5 ng/L) ≥ benzotriazole (61.2 ± 18.8 ng/L) ≥ trimethoprim (59.1 ± 30.4 ng/L) ≥ cetirizine (33.7 ± 19.6 ng/L) ≥ codeine (26.7 ± 57.2 ng/L) ≥ naproxen (25.7 ± 11.3 ng/L) ≥ venlafaxine (21.6 ± 16.3 ng/L) ≥ acetaminophen (17.7 ± 25.8 ng/L) ≥ benzoylecgonine (9.6 ± 5.1 ng/L) ≥ methamphetamine (8.6 ± 6.4 ng/L) ≥ diclofenac (5.2 ± 7.9 ng/L). The large standard deviations indicate the high temporal variations in CECs releases in freshwater. The silver lining is that in the final drinking water, CECs concentrations are greatly reduced, with percentage removals in the range of 9 % (diclofenac) to 75 % (efavirenz). Nonetheless, in LMICs tangible limits and regulatory frameworks for the effective removal of CECs from drinking water, along with more robust polishing techniques such as activated carbon treatment, are missing and should be introduced to avoid the worst effects of CECs exposure.

Comparative Analysis of Human vs. Machine Stone Polishing Techniques: A Comprehensive Study on Cost, Productivity, Health, and Risk Management

Comparative Analysis of Human vs. Machine Stone Polishing Techniques: A Comprehensive Study on Cost, Productivity, Health, and Risk Management

Effect of Polishing Systems on the Surface Roughness and Color Stability of Aged and Stained Bulk-Fill Resin Composites.

The aim of this study is to investigate how two different polishing techniques affect the color stability, surface roughness, and changes in surface morphology of aged and coffee-stained bulk-fill resin composites. A total of 112 disc-shaped samples were prepared using Omnichroma Flow Bulk (OB), Charisma Bulk Flow One (CB), Estelite Bulk Fill Flow (EB), and Estelite Sigma Quick (control). Samples were divided into two subgroups (n = 16) and aged using thermocycling. A profilometer was used to measure the surface roughness (Ra) and a spectrophotometer was used for color stability (ΔE00). The EB group had the highest Ra values both before aging (disc: 0.23 ± 0.05, twist: 0.42 ± 0.05) and after aging (discs: 0.28 ± 0.04, twist: 0.46 ± 0.05). The OB group had the highest ΔE00 values before and after aging (discs: 3.06 ± 0.54, twist 3.05 ± 0.41) and the highest after coffee-staining (discs: 3.75 ± 0.70, twist: 3.91 ± 0.57). Re-polishing reduced the ΔE00 values in all materials but did not restore all to clinically acceptable levels. According to the results of this study, it can be concluded that the surface roughness and color stability of resin composites are notably influenced by the polishing technique, aging process, and coffee staining. Specimens that were polished using the multi-stage Super-Snap discs consistently exhibited smoother surfaces across all bulk-fill resin composites compared to those polished with the two-stage Diacomp plus Twist.

Low loss ridge waveguides on the hybrid single crystalline silicon and lithium niobate thin films

The hybridization of silicon (Si) thin film and lithium niobate (LN) thin film with remarkable properties, including the excellent optical properties of LN, excellent electrical properties and mature processing advantages of Si, can provide an important material platform for integrated photonic applications. In this work, a 4-inch single crystalline Si thin film wafer was prepared using wafer bonding, grinding and polishing techniques on LN thin film substrate. The films were characterized by using high-resolution transmission electron microscopy (HRTEM). The interplanar spacings and strain of Si film were calculated by analysis of high-resolution X-ray diffraction (HRXRD). Si ridge straight waveguides were fabricated on the hybrid thin films, and the transmission loss was 1.2 dB/cm. The near-field mode distribution of the waveguide was investigated by combining FDTD (Finite-Difference Time-Domain) simulation and end coupling measurement.

Overview of Patents on Diamond Polishing Apparatus

Diamond, with its unparalleled combination of physical and chemical attributes, occupies a critical role in future technological domains; yet, the caliber of its surface quality is decisively linked to its performance within advanced applications. Thus, engaging in super-precision processing to elevate the surface integrity of diamond constitutes a central tenet for broadening its application potential. This paper systematically dissects patents pertaining to diamond polishing apparatus, not only revealing the distinctive strengths and pragmatic features inherent in contemporary diamond polishing technology but also identifying limitations and avenues for refinement within current polishing methodologies. With the continuous expansion and deepening of modern industrial sectors, there is a growing demand for diversified and specialized material performance. Diamond, as a pivotal raw material, exhibits immense potential in its composite applications with a variety of other materials, forming an entire industrial chain that has permeated numerous industries. Throughout the comprehensive preparation process of diamond, from rough stone to finished product, polishing techniques play a critical role, representing an indispensable step in enhancing the surface quality and functional attributes of diamond products. This study provides a comprehensive review of representative patents in the field of diamond polishing apparatus, analyzing the distinctive functional attributes and performance characteristics of various diamond polishing devices. The study classifies polishing devices according to their design characteristics and application domains into five distinct categories: polishing apparatuses specifically designed for single-crystal diamonds, systems tailored for the polishing of complex curved surface diamonds, laser-assisted diamond polishing setups, structurally-enhanced diamond polishing equipment, and functionally-specialized diamond polishing tools. The analysis underscores the unique innovative aspects and advantages demonstrated by each patent in addressing the inherent limitations of traditional polishing devices. Moreover, it elucidates the technological constraints and developmental gaps that exist within each respective area. Presently, the essence of polishing technology research revolves around the precision and efficacy in polishing single-crystal diamonds and intricate curved diamond surfaces, alongside the structural innovation and functional refinement of polishing apparatuses. Predominant among these devices are those that largely depend on mechanical polishing methods integrated with laser-assisted and chemical mechanical polishing methodologies, where patent advancements are mainly geared towards boosting efficiency, guaranteeing surface integrity, fortifying adaptability across different operating scenarios, and incorporating multiple functionalities. Concurrently, considerable attention is given to enhancing the ecological performance of these systems. There remains a significant underdevelopment and limited widespread application of diamond polishing apparatus in advanced technologies such as thermal chemical polishing and ion beam polishing. This gap presents an enormous potential for innovation breakthroughs and diversified advancements in polishing techniques. There is an urgent need for increased investment to propel the development and integration of automated control systems, intelligent monitoring, and deeper exploration of new materials within polishing technology. The aim is to realize higher-level automated and intelligent diamond polishing solutions that can achieve more efficient, precise, and environmentally friendly polishing objectives.

Influence of Low pH on the Microhardness and Roughness Surface of Dental Composite-A Preliminary Study.

Dental composites are gaining great popularity in restorative dentistry because of their aesthetic appeal and capacity to replicate the natural color of teeth. Nevertheless, their lifespan and durability rely on various factors, such as the polishing technique and the environmental conditions they are exposed to. The study aimed to assess the influence of the method of final polishing of dental composite on the surface roughness and microhardness of materials also considering the environment of different pHs. Disc-shaped samples (5 mm diameter and 2 mm thickness) have been prepared for microhardness and roughness tests from two dental composites: A2 Clearfil Majesty ES 2 Classic and A2D Clearfil Majesty Premium. One-third of samples were polished with polishing discs, OptiDisc, another one-third of samples were polished with Eve Diacomp Twist rubbers and polishing brush with diamond particles, and rest of the samples were stored without any polishing (the control group). Tested materials were incubated in distilled water or acidic buffer (pH = 2) for 3 weeks at a temperature of 37 °C. No statistically significant differences were found for roughness for the two materials tested after incubation in liquids. A decrease in Vicker microhardness was found for Clearfil Majesty ES 2 Classic after soaking in a low pH liquid, and no such relationship was found for Clearfil Majesty Premium. The improved resistance of these materials to the negative oral environment may result in the longer survival of composite restorations in patients with poor diet or diseases, causing a decrease in oral pH.

Nucleation bubble boundary layer theory for ultra-fast electrochemical polishing of additive manufacturing components

The application of electrochemical-based polishing techniques, including electrochemical polishing (ECP) and plasma electrolytic polishing (PEP), to improve the surface quality of additive manufacturing (AM) components is challenged by the high amplitudes and long spatial wavelengths of roughness, which cause pre-polishing procedures to be indispensable. In this study, a nucleation bubble boundary layer (NBBL) mechanism for enhanced electrochemical-based polishing performance is revealed to solve this problem, namely nucleation bubble electrochemical polishing (NBEP). The NBBL is constructed on the anode surface via electrolytic oxygen evolution and nucleate boiling, and is activated by regulating the temperature and electric potential. The experiments verify a model of NBBL consisting of an inner adherent layer and outer diffusion layer (ODL). Simulations and experiments demonstrate that the polishing mechanism is based on the combined current-limiting effect of individual adherent bubbles and the ODL, which differentiates the anodic dissolution rates at the peaks and valleys of a wide range of spatial wavelengths with their electrical resistance. The bubble dynamics also enhance mass transfer, further improving the polishing efficiency. The experimental results show that NBEP is capable of reducing the surface roughness of AM stainless steel 316 L from Ra of 10.22 μm to 0.71 μm, and eliminating the spatial wavelengths of 200–400 μm in 8 min, which cannot be achieved by either ECP or PEP. The polishing current density also increased from 0.25 (ECP) and 0.48 (PEP) to 2 A/cm2 in NBEP. Finally, a prediction model that accurately describes the ultimate roughness achieved by NBEP as a function of the minimum cavity size is established. The NBEP can be directly followed by PEP or ECP to achieve an optimal surface finish of Ra <70 nm for AM parts. The NBEP method considerably enhances the polishing performance of electrochemical-based systems for AM components, as well as expands the application range of electrochemical-based polishing techniques.

In vitro study on the impact of various polishing systems and coffee staining on the color stability of bleach-shaded resin composite

ObjectiveTo evaluate the effects of different polishing techniques and coffee staining on the color stability of four commercially available bleach-shade composite resins, namely microhybrid, nanohybrid, nanofilled, and injectable nanohybrids.Material and methodsA total of 224 discs (8 mm diameter and 2 mm thickness) were fabricated from four different bleach-shade composite resins, namely microhybrid (Gradia Direct Anterior), nanohybrid (Palfique LX5), nanofilled (Filtek Universal), and injectable nanohybrid (flowable G-aenial universal injectable). The composite resin groups were polished via four techniques: no polishing, 4-step polishing using aluminum oxide discs, 3-step polishing using silicon rubber diamond discs, and one-step polishing. Half of each group was immersed in water, while the other half was immersed in coffee for 12 days (n = 7). Colors were measured using a clinical spectrophotometer, and color differences were calculated (ΔE). The results were analyzed statistically.ResultsThe alterations in color were significantly influenced by the techniques employed for finishing and polishing techniques, composite resin type, and degree of coffee staining. Regardless of the polishing technique and storage medium, different material types showed a significant color change (ΔE) at P < 0.001. Filtek exhibited the most significant color change, followed by Gradia and Palfique, with no significant differences between them. In addition, Different polishing techniques resulted in significant color changes (P < 0.001). The highest degree of color change was seen in the no-polishing group, followed by the 4-step and 1-step polishing groups, with negligible differences between each other. Also, Storage media had a significant effect on ΔE values.ConclusionAppropriate finishing and polishing procedures can improve the color stability of bleach-shaded composite resins. Coffee has a deleterious effect on color; however, injectable flowable nanohybrid composites are more resistant to staining.

Efficient construction and convergence analysis of sparse convolutional neural networks

In this paper, a new variant of convolutional neural network (CNN) based on L1 regularization is proposed. The main consideration is to generate a sparse weight matrix, i.e., to generate a sparse neural network model. To some extent, L1 regularization prevents the occurrence of overfitting and effectively improves the learning efficiency of the network. Unfortunately, the L1 regularization term is non-smooth, which leads to the occurrence of oscillations in experiments and poses a great challenge to the theoretical analysis. So, we overcome this drawback by using polishing techniques and rigorously prove the monotonicity of the error function and the strong and weak convergence theorems of the algorithm. Finally, numerical simulations on several data sets support our theoretical results and the superiority of the proposed algorithm.

Temporal contrast degradation from mid-spatial-frequency surface error on stretcher mirrors

Temporal contrast degradation due to mid-spatial-frequency error in chirped-pulse amplification stretcher optics is studied. Third-order cross-correlation measurements reveal a temporal peak that appears when using two different mirrors processed by magnetorheological finishing, despite an improvement in rms roughness compared to a third unprocessed mirror. Simulations based on measured power spectral density show how the actual impact on contrast is different from measurements using a typical bandwidth-limited third-order cross correlator. Strategies are proposed to avoid this type of contrast degradation while exploiting computer numerically controlled polishing techniques for enhancement of surface figure and roughness.

Effect of Process Parameters on the Roughness and Wetting Characteristics of SS304 Surfaces Using Electrolytic and Plasma Electrolytic Polishing Techniques

Metallic parts manufactured by conventional machining and additive manufacturing techniques possess poor surface quality and require post-processing operations before their end-use. Many methods exist for the post-processing of parts with free-form surfaces. In this study, two of the most used polishing techniques, electrolytic polishing (EP) and plasma electrolytic polishing (PeP), were investigated to understand the morphology of the resultant surface after both techniques. Pilot experiments suggested that an aqueous solution of ammonium sulphate is the most effective electrolyte for both the polishing techniques in terms of the lowest achievable value of average surface roughness ( Ra ). A systematic investigation of the electrolyte concentration, applied voltage, and polishing time revealed an identical dependence on all these process parameters: First, a decrease and then an increase in Ra. A minimum Ra of 0.63 μm and 0.49 μm were achieved with EP and PeP, respectively. Samples polished by PeP possess high gloss with negligible changes to the shape and form of the samples. Furthermore, static contact angle measurements with water revealed that surfaces treated with PeP showed higher hydrophilicity compared to those polished with EP. This can be attributed to the lower Ra value achieved with PeP.

Polishing methods for composites restoration: the influence on human gingival fibroblasts behaviour

BackgroundCarious/Non-carious cervical lesions with gingival recessions may require both dental and periodontal reconstructive therapy, where flaps/grafts may be placed in contact with a dental filling material. Human Gingival Fibroblasts (HGF-1) response during the early phase of healing could vary according to the procedures employed to cure the dental composite. Moreover, oxygen diffusion into dental composite inhibits the polymerization reaction, creating an oxygen-inhibited layer (OIL) that presents residual unreacted monomers. The aim of this study was to assess the effect of different polishing techniques and OIL on HGF-1.MethodsComposite discs polished with different techniques (diamond rubber, abrasive discs and tungsten carbide burr) were used. An additional not polished smooth group obtained with and without OIL was used as control. Samples were physically characterized through the analysis of their hydrophilicity and surface topography through contact angle measurement and SEM, respectively; afterwards the biologic response of HGF-1 when cultured on the different substrates was analyzed in terms of cytotoxicity and gene expression.ResultsThe finishing systems caused alterations to the wettability, even if without a proportional relation towards the results of the proliferation essay, from which emerges a greater proliferation on surfaces polished with one-step diamond rubber and with abrasive discs as well as a direct effect of the glycerin layer, confirming that surface roughness can heavily influence the biological response of HGF-1.ConclusionsSurfaces wettability as well as cellular behavior seem to be affected by the selection of the finishing system used to lastly shape the restoration. Especially, the presence of OIL act as a negative factor in the regards of human gingival fibroblasts. The present study may provide the first clinical instruction regarding the best polishing system of composite material when the restoration is placed directly in contact with soft tissue cells. Understanding HGF-1 behavior can help identifying the polishing treatment for direct restoration of carious/non-carious cervical lesions associated with gingival recessions.

Efficient Ablation, further GHz Burst Polishing, and Surface Texturing by Ultrafast Laser

A large variety of ultrafast laser‐matter interaction regimes and different processed surface finishing qualities of stainless steel can be achieved by varying the laser processing parameters. The optimization of the laser fluence to the most efficient ablation also leads to the lowest surface roughness of the ablated material. High laser fluence together with a high pulse repetition rate leads to heat accumulation, which results in the formation of microstructures with various morphology and scales. The use of GHz bursts allows a rough stainless‐steel surface to be smoothed and even polished. In this work, the fast and high‐quality milling of 2.5D cavities is demonstrated. Laser beam spot optimization is used to increase the throughput of the high‐power femtosecond laser (67.8 W), resulting in an ablation rate of 13 mm3 min−1. The complex cavities are produced by laser milling and cutting in layers. The formation of surface structures on stainless steel because of laser irradiation has been demonstrated. The possibilities of further GHz burst polishing are examined on previously laser‐milled stainless steel using with lowest possible surface roughness. The ability to polish the surface with microstructures below the original roughness is demonstrated by bursts of ultrashort pulses with a repetition rate in the GHz range. It has been demonstrated that mold milling in stainless steel designed for LED diffusers can be fabricated using a modern femtosecond laser source together with beam size optimization technique for efficient ablation with low surface roughness, layer‐by‐layer milling techniques, and GHz burst polishing techniques.