Search Results (88)

Titanium–aluminum–vanadium (Ti6Al4V) is a material chosen for spine, orthopedic, and dental implants due to its combination of desirable mechanical and biological properties. Lasers have been used to modify metal surfaces, enabling the generation of a surface on Ti6Al4V with distinct micro- and nano-scale structures. Studies indicate that topography with micro/nano features of osteoclast resorption pits causes bone marrow stromal cells (MSCs) and osteoprogenitor cells to favor differentiation into an osteoblastic phenotype. This study examined whether the biological response of human MSCs to Ti6Al4V surfaces is sensitive to laser treatment-controlled micro/nano-topography. First, 15 mm diameter Ti6Al4V discs (Spine Wave Inc., Shelton, CT, USA) were either machined (M) or additively manufactured (AM). Surface treatments included no laser treatment (NT), nanosecond laser (Ns), femtosecond laser (Fs), or nanosecond followed by femtosecond laser (Ns+Fs). Surface wettability, roughness, and surface chemistry were determined using sessile drop contact angle, laser confocal microscopy, X-ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM). Human MSCs were cultured in growth media on tissue culture polystyrene (TCPS) or test surfaces. On day 7, the levels of osteocalcin (OCN), osteopontin (OPN), osteoprotegerin (OPG), and vascular endothelial growth factor 165 (VEGF) in the conditioned media were measured. M NT, Fs, and Ns+Fs surfaces were hydrophilic; Ns was hydrophobic. AM NT and Fs surfaces were hydrophilic; AM Ns and Ns+Fs were hydrophobic. Roughness (Sa and Sz) increased after Ns and Ns+Fs treatment for both M and AM disks. All surfaces primarily consisted of oxygen, titanium, and carbon; Fs had increased levels of aluminum for both M and AM. SEM images showed that M NT discs had a smooth surface, whereas AM surfaces appeared rough at a higher magnification. Fs surfaces had a similar morphology to their respective NT disc at low magnification, but higher magnification revealed nano-scale bumps not seen on NT surfaces. AM Fs surfaces also had regular interval ridges that were not seen on non-femto laser-ablated surfaces. Surface roughness was increased on M and AM Ns and Ns+Fs disks compared to NT and Fs disks. OCN was enhanced, and DNA was reduced on Ns and Ns+Fs, with no difference between them. OPN, OPG, and VEGF levels for laser-treated M surfaces were unchanged compared to NT, apart from an increase in OPG on Fs. MSCs grown on AM Ns and Ns+Fs surfaces had increased levels of OCN per DNA. These results indicate that MSCs cultured on AM Ns and AM Ns+Fs surfaces, which exhibited unique roughness at the microscale and nanoscale, had enhanced differentiation to an osteoblastic phenotype. The laser treatments of the surface mediated this enhancement of MSC differentiation and warrant further clinical investigation. Full article

In this study, a facile and mask-free femtosecond laser direct writing (FLDW) approach is proposed to fabricate porous graphene (FLIG) patterns directly on polyimide (PI) substrates. By systematically adjusting the laser scanning spacing (10–25 μm), denser and more continuous microstructures are obtained, resulting in significantly enhanced thermal sensitivity. The optimized sensor demonstrated a temperature coefficient of 0.698% °C⁻¹ within the range of 40–120 °C, with response and recovery times of 10.3 s and 20.9 s, respectively. Furthermore, it exhibits remarkable signal stability across multiple thermal cycles, a testament to its reliability in extreme conditions. Moreover, the sensor was successfully integrated into a 3D-printed robotic platform, achieving both contact and non-contact temperature detection. These results underscore the sensor’s practical adaptability for real-time thermal sensing. This work presents a viable and scalable methodology for fabricating high-performance FLIG-based flexible temperature sensors, with extensive application prospects in wearable electronics, electronic skin, and intelligent human–machine interfaces. Full article

Given the exceptional capabilities of femtosecond laser processing in achieving high-precision ablation for air-film cooling hole fabrication on turbine blades, it is imperative to develop an advanced monitoring methodology that enables real-time feedback control to automatically terminate the laser upon complete penetration detection, thereby effectively preventing backside damage. To tackle this issue, a spectrum-domain coherent imaging technique has been developed. This innovative approach adapts the fundamental principle of fiber-based Michelson interferometry by integrating the air-film hole into a sample arm configuration. A broadband super-luminescent diode with a 830 nm central wavelength and a 26 nm spectral bandwidth serves as the coherence-optimized illumination source. An optimal normalized reflectivity of 0.2 is established to maintain stable interference fringe visibility throughout the drilling process. The system achieves a depth resolution of 11.7 μm through Fourier transform analysis of dynamic interference patterns. With customized optical path design specifically engineered for through-hole-drilling applications, the technique demonstrates exceptional sensitivity, maintaining detection capability even under ultralow reflectivity conditions (0.001%) at the hole bottom. Plasma generation during laser processing is investigated, with plasma density measurements providing optical thickness data for real-time compensation of depth measurement deviations. The demonstrated system represents an advancement in non-destructive in-process monitoring for high-precision laser machining applications. Full article

Superhydrophobic surfaces have garnered significant attention due to their pivotal roles in various fields. Femtosecond laser technology provides a feasible means for inducing superhydrophobic microstructures on material surfaces. However, due to the unclear influence mechanisms of process parameters, as well as the high cost and time-consuming nature of experiments, identifying the optimal femtosecond laser processing parameters within the process space remains a significant challenge. To address this issue, a process optimization framework that couples machine learning and genetic algorithms was proposed and successfully applied to the optimization of femtosecond laser-induced groove structures on TC4 alloy surfaces. Firstly, based on 64 sets of experimental data, the effects of the power, scanning speed, and scanning interval on the micro-groove structures and their wetting properties were discussed in detail. Furthermore, by utilizing this small sample dataset, various machine learning algorithms were employed to establish a prediction model for the contact angle, among which support vector regression demonstrated the optimal predictive accuracy. Three additional dimensional variables, i.e., the number of effective pulses, energy deposition rate, and roughness, were also added to the original dataset vectors as extra dimensions to participate in and guide the model training process. The prediction model was further coupled into a genetic algorithm to achieve the quantitative design of femtosecond laser processing. Compared to the best hydrophobicity in the original dataset, the contact angle of the designed process was improved by 5.5%. The proposed method provides an ideal solution for accurately predicting wetting properties and identifying optimal processes, thereby accelerating the development and application of femtosecond laser-induced superhydrophobic microstructures. Full article

This study is a comprehensive experimental and computational investigation into high-resolution laser beam diagnostics, combining classical statistical techniques, numerical image processing, and machine learning-based predictive modeling. A dataset of 50 sequential beam profile images was collected from a femtosecond fiber laser operating at a central wavelength of 780 nm with a pulse duration of approximately 125 fs. These images were analyzed to extract spatial and temporal beam characteristics, including centroid displacement, Full Width at Half Maximum (FWHM), ellipticity ratio, and an asymmetry index. All parameters were derived using intensity-weighted algorithms and directional cross-sectional analysis to ensure accurate and consistent quantification of the beam’s dynamic behavior. Linear regression models were applied to horizontal and vertical intensity distributions to assess long-term beam stability. The resulting predictive trends revealed a systematic drift in beam centroid position, most notably along the vertical axis, and a gradual broadening of the horizontal FWHM. The modeling further showed that vertical intensity increased over time while horizontal intensity displayed a slight decline, reinforcing the presence of axis-specific fluctuations. These effects are attributed to minor optical misalignments or thermally induced variations in the beam path. By integrating deterministic analysis with data-driven forecasting, this methodology offers a robust framework for real-time beam quality evaluation. It enhances sensitivity to subtle distortions and supports the future development of automated, self-correcting laser systems. The results underscore the critical role of continuous, high-resolution monitoring in maintaining beam stability and alignment precision in femtosecond laser applications. Full article

Multi-focal microlens arrays provide notable advantages over mono-focal counterparts, such as multi-scale imaging capabilities and optical aberration correction. However, existing multi-focal microlens arrays fabricated on continuous surfaces are incapable of achieving confocal imaging. As a result, multiple focus adjustments are required to acquire comprehensive image data, thereby complicating system design and increasing operational duration. To overcome this limitation, a stepped confocal surface microlens array is proposed, capable of simultaneously capturing images with multiple depths of field, various field-of-view scales, and different resolutions—without the need for additional focus adjustments. A combination of femtosecond laser processing and chemical etching was employed to fabricate microlenses with varying curvatures on a stepped fused silica substrate, which was subsequently used as a mold. The final stepped confocal microlens array was replicated via polydimethylsiloxane (PDMS) molding. Preliminary experimental analyses were carried out to determine the relationship between processing parameters and the resulting focal lengths. By precisely controlling these parameters, the fabricated stepped confocal microlens array successfully enabled confocal imaging, allowing for the simultaneous acquisition of diverse image data. This microlens array shows great potential in advancing lightweight, integrated, and highly stable optical systems for applications in optical sensing, spatial positioning, and machine vision. Full article

Ultrafast laser systems, implemented at the ELI-NP, require exceptional beam quality and spatial stability due to their femtosecond pulse durations and extremely high peak powers. This work presents a diagnostic and computational framework for analyzing the ELI-NP Front-End beam characteristics, where spatial coherence and precise pulse shaping are essential for reliable amplification and experimental consistency. The methodology integrates classical beam diagnostics with image processing and machine learning tools to evaluate anomalies based on high-resolution beam profile images. We use centroid tracking to monitor pointing fluctuations, statistical intensity analysis to detect energy instabilities, and Sobel-based edge detection to evaluate beam sharpness and extract structural features from the beam image. Geometric parameters such as ellipticity, roundness, and symmetry indicators are extracted and examined over time. The system applies an unsupervised Isolation Forest algorithm to detect subtle or short-lived anomalies, identifying irregularities without relying on predefined thresholds. These diagnostics are supported by visual plots and statistical summaries, offering a clear picture of the beam’s behavior under real operating conditions. Results confirm that this integrated approach effectively captures major and minor beam instabilities, making it a practical tool for continuous monitoring and performance optimization in ultrafast laser systems. Full article

Precision micromilling is currently widely used for the fabrication of injection mold inserts for the mass production of microfluidic devices. However, for complex devices with micrometer-scale and high density of structures, micromilling results in high production times and costs for production runs of hundreds or thousands of units. Femtosecond laser (fs-laser) technology has emerged as a promising solution for high-precision micromachining. This study analyzes the potential of fs-laser micromachining for the fabrication of injection mold inserts for the large-scale production of thermoplastic microfluidic devices. For the evaluation of technology, a reference design was defined. The parameters of the fs-laser process were optimized to achieve high resolution of the structures and optimal surface quality, aiming to minimize production times and costs while ensuring the quality of the final part. The microstructures were replicated in two different grades of COC (Cyclic Olefin Copolymer) by injection molding. The dimensional tolerance of the structures and the surface finish achieved both in the insert and the polymer parts were characterized by scanning electron microscopy (SEM) and confocal microscopy. The surface quality of the final parts and its suitability for microfluidic fabrication were also assessed performing chemical bonding tests. The fs-laser machining process has shown great potential for the mass production of microfluidic devices. The developed process has enabled for a reduction of up to 90% in the fabrication times of the insert compared to micromilling. The parts exhibited very smooth surfaces, with roughness values (Sa) of 64.6 nm for the metallic insert and 71.8 nm and 72.9 nm for the COC E-140 and 8007S-04 replicas, respectively. The dimensional tolerance and the surface quality need to be improved to be competitive with the finishes achieved with precision micromilling. Nonetheless, there is still room for improvement considering the significant reduction in the production times through new laser processing strategies. Full article

Tools with micro-textures have found wide application in cutting difficult machining materials. The cutting performance of tools is closely related to the arrangement, morphology, and size parameters of micro-textures. In this research, micro-pit tools were used in turning GH4169 in spray cooling. The effect of micro-pit parameters on tool wear was investigated through simulation and cutting experiments. In simulation, a model of cutting GH4169 in spray cooling was built to analyze the wear of micro-pit tools with different parameters, and the optimal combination of micro-pit parameters with excellent anti-wear performance was obtained: when the distance between the micro-pit and tool nose is 60 μm, the diameter of micro-pits is 70 μm, and the pit spacing is 100 μm. In the cutting experiment, micro-pit textures with different parameters were fabricated by femtosecond laser, and cutting experiments were conducted in spray cooling to analyze the wear on the rake face of micro-pit tools. Furthermore, Ansys Fluent was used to simulate the dynamic pressure of oil film on the surface of micro-pits, and the anti-wear mechanism of micro-textured tools was verified. This research provides technical reference for the design and development of micro-textured tools. Full article

Laser micro-machining is a rapidly growing technique to create, manufacture and fabricate microstructures on different materials ranging from metals and ceramics to polymers. Micro- and nano-machining on different materials has been helpful and useful for various biomedical applications. This study focuses on the micro-machining of innovative barbed sutures using an ultrashort pulse laser, specifically a femtosecond (fs) laser system. Two bioresorbable polymeric materials, namely, catgut and poly (4-hydroxybutyrate) (P4HB), were studied and micro-machined using the femtosecond (fs) laser system. The optimized laser parameter was used to fabricate two different barb geometries, namely, straight and curved barbs. The mechanical properties were evaluated via tensile testing, and the anchoring performance was studied by means of a suture–tissue pull-out protocol using porcine dermis tissue which was harvested from the medial dorsal site. Along with the evaluation of the mechanical and anchoring properties, the thermal characteristics and degradation profiles were assessed and compared against mechanically cut barbed sutures using a flat blade. The mechanical properties of laser-fabricated barbed sutures were significantly improved when compared to the mechanical properties of the traditionally/mechanically cut barbed sutures, while there was not any significant difference in the anchoring properties of the barbed sutures fabricated through either of the fabrication techniques. Based on the differential scanning calorimetry (DSC) results for thermal transitions, there was no major impact on the inherent material properties due to the laser treatment. This was also observed in the degradation results, where both the mechanically cut and laser-fabricated barbed sutures exhibited similar profiles throughout the evaluation time period. It was concluded that switching the fabrication technique from mechanical cutting to laser fabrication would be beneficial in producing a more reproducible and consistent barb geometry with more precision and accuracy. Full article

The accuracy and reliability of small-scale mechanical tests remain doubtful due to significant dependence of the obtained mechanical properties on specimen size. Mesoscale tensile tests with specimen sizes ranging from 10 μm to 1 mm are capable of obtaining bulk-like properties but are rarely applied to hexagonal close-packed metals. In this study, well-designed comparative tensile tests were carried out on a Zircaloy-4 alloy with a grain size of 4 μm using femtosecond laser-machined mesoscale specimens with a thickness of about 60 μm, sub-sized specimens with a thickness of about 1.3 mm, and standard specimens with a thickness of 4 mm. The quantitative results revealed that irrespective of the small specimen dimensions, the yield strength, tensile strength, and tensile ductility are only approximately 10.4%, 5.2%, and 13% lower than those of the standard specimens, respectively. This clearly demonstrates that the mechanical properties can be assessed with satisfactory accuracy by mesoscale tensile tests. The comparatively greater deviation of the yield strength at the mesoscale arises from the disappearance of yield point behavior, while the reduced tensile ductility is associated with the larger volume fraction of surface grains. The surface grains are characterized by more surface dislocation sources and deform with weaker constraints from neighboring grains, leading to smooth plastic yielding and slightly reduced strain hardening at the mesoscale. Full article

Gallium nitride (GaN) exhibits distinctive physical and chemical properties that render it indispensable in a multitude of electronic and optoelectronic devices. Given that GaN is a typical hard and brittle material that is difficult to machine, femtosecond laser technology provides an effective and convenient tool for processing such materials. However, GaN undergoes complex physical and chemical changes during high-power ablation, which poses a challenge to high-precision processing with controllable geometry. In this study, the quantitative relationship between the parameters of a single-pulse femtosecond laser and GaN ablation morphology was investigated using isotherm distribution. A multiphysics model using COMSOL Multiphysics^® was developed to generate the isothermal distributions. Experiments were conducted on the femtosecond laser ablation of GaN at various single-pulse energies, and the resulting ablation morphologies were compared with the predictions from the multiphysics model. The comparison demonstrated that the calculated isotherm distribution accurately predicted not only the ablation diameter and depth but also the crater shape across a broad range of laser fluences. The predicted errors of the ablation diameters and depths were within 4.71% and 10.9%, respectively. The root mean square error (RMSE) and coefficient of determination (R²) were employed to evaluate the prediction errors associated with the crater shapes, which fell within the range of 0.018–0.032 μm and 0.77–0.91, respectively. This study can provide an important reference for utilizing femtosecond lasers in the precise ablation of GaN to achieve desired geometries. Full article

Surface texturing plays a vital role in enhancing tribological performance, reducing friction and wear, and improving durability in industrial applications. This study introduces an innovative approach by employing machine learning models—specifically, decision trees, support vector machines, and artificial neural networks—to predict optimal femtosecond laser surface texturing parameters for tungsten carbide tested with WS₂ and TiCN coatings. Traditionally, the selection of laser parameters has relied heavily on a trial-and-error method, which is both time-consuming and inefficient. By integrating machine learning, this study advances beyond conventional methods to accurately predict the depth and quality of textured features. The ANN demonstrated superior predictive accuracy among the models tested, outperforming SVM and Decision Trees. This machine learning-based approach not only optimizes the surface texturing process by reducing experimental effort but also enhances the resultant surface performance, making it well-suited for applications in sectors such as automotive and oil and gas. Full article

Femtosecond laser processing combines highly accurate structuring with low residual heating of materials, low thermal damage, and nonlinear absorption processes, making it suitable for the machining of transparent brittle materials. However, with high average powers and laser pulse repetition rates, residual heating becomes relevant. Here, we present a study of the femtosecond laser pulse-on-demand operation regime, combined with regular scanners, aiming to improve throughput and quality of processing regardless of the scanner’s capabilities. We developed two methods to define the needed pulse-on-demand trigger sequences that compensate for the initial accelerating scanner movements. The effects of pulse-on-demand operation were studied in detail using direct process monitoring with a fast thermal camera and indirect process monitoring with optical and topographical surface imaging of final structures, both showing clear advantages of pulse-on-demand operation in precision, thermal effects, and structure shape control. The ability to compensate for irregular scanner movement is the basis for simplified, cheaper, and faster femtosecond laser processing of brittle and heat-susceptible materials. Full article

Vibration sensors are widely applied in the detection of faults and analysis of operational states in engineering machinery and equipment. However, commercial vibration sensors with a feature of high hardness hinder their usage in some practical applications where the measured objects have irregular surfaces that are difficult to install. Moreover, as the operating environments of machinery become increasingly complex, there is a growing demand for sensors capable of working in wet and humid conditions. Here, we present a flexible, superhydrophobic vibration sensor with parallel microcracks. The sensor is fabricated using a femtosecond laser direct writing ablation strategy to create the parallel cracks on a PDMS film, followed by spray-coating with a conductive ink composed of MWCNTs, CB, and PDMS. The results demonstrate that the developed flexible sensor exhibits a high-frequency response of up to 2000 Hz, a high acceleration response of up to 100 m/s², a water contact angle as high as 159.61°, and a linearity of 0.9812 between the voltage signal and acceleration. The results indicate that the sensor can be employed for underwater vibration, sound recognition, and vibration monitoring in fields such as shield cutters, holding significant potential for mechanical equipment vibration monitoring and speech-based human–machine interaction. Full article