Over millions of years of natural evolution, organisms have developed nearly perfect structures and functions. The self-fabrication of organisms serves as a valuable source of inspiration for designing the next-generation of structural materials, and is driving the future paradigm shift of modern materials science and engineering. However, the complex structures and multifunctional integrated optimization of organisms far exceed the capability of artificial design and fabrication technology, and new manufacturing methods are urgently needed to achieve efficient reproduction of biological functions. As one of the most valuable advanced manufacturing technologies of the 21st century, laser processing technology provides an efficient solution to the critical challenges of bionic manufacturing. This review outlines the processing principles, manufacturing strategies, potential applications, challenges, and future development outlook of laser processing in bionic manufacturing domains. Three primary manufacturing strategies for laser-based bionic manufacturing are elucidated: subtractive manufacturing, equivalent manufacturing, and additive manufacturing. The progress and trends in bionic subtractive manufacturing applied to micro/nano structural surfaces, bionic equivalent manufacturing for surface strengthening, and bionic additive manufacturing aiming to achieve bionic spatial structures, are reported. Finally, the key problems faced by laser-based bionic manufacturing, its limitations, and the development trends of its existing technologies are discussed.

Based on microstructure characteristics of Meretrix lusoria shell and Rapana venosa shell, bionic coupling layered B₄C/5083Al composites with different layered structures and hard/soft combination models were fabricated via hot pressed sintering. The simplified bionic coupling models with hard and soft layers were similar to layered structure and hardness tendency of shells, guiding the bionic design and fabrication. B₄C/5083Al composites with various B₄C contents and pure 5083Al were treated as hard and soft layers, respectively. Hot pressed sintering maintained the designed bionic structure and enhanced high bonding strength between ceramics and matrix. Compared with B₄C/5083Al composites, bionic layered composites exhibited high mechanical properties including flexural strength, fracture toughness, compressive strength and impact toughness. The hard layers absorbed applied loads in the form of intergranular fracture. Besides connection role, soft layers restrained slabbing phenomenon and reset extension direction of cracks among layers. The coupling functions of bionic composites proved the feasibility and practicability of bionic fabrication, providing a new method for improvement of ceramic/Al composite with properties of being lightweight and high mechanical strength.

The Typha leaf has a structure of lightweight cantilever beam, exhibiting excellent mechanical properties with low density. Especially, the leaf blade evolved high strength and low density with high porosity. In this paper, the structure of Typha leaf was characterized by microcomputed tomography (Micro-CT) and scanning electron microscopy (SEM), and the relationship with flexural properties was analyzed. The three-point bending test was performed on leaves to examine flexural properties, which indicated that the flexural properties vary from the base to the apex in gradient. The cross-sectional geometry shape of the leaf blade presented a strong influence on the optimized flexural stiffness. The load carrying capacity of the leaf depended on the development level of the epidermal tissue, the vascular bundle, the mechanical tissue, and the geometric properties. The investigation can be the basis for lightweight structure design and the application in the bionic engineering field.

NiTi alloys are commonly used in many fields such as aerospace, mechanical engineering due to their excellent mechanical properties and shape memory effect. In recent years, the emergence of selective laser melting (SLM) technology provides a new method for the preparation of NiTi parts. But the surface corrosion failure of SLM-NiTi is the most common problem. This paper mainly focuses on the research of femtosecond laser shock peening of the surface of SLM-NiTi alloy to improve the corrosion resistance. Selecting different scanning space (1 μm, 3 μm, 5 μm, 10 μm), and analyze the surface morphology of the material through the OM, SEM, EDS and white light interferometer, and investigate the surface nanohardness and corrosion resistance through nanoindentation and electrochemical testing. The research results show that part of the TiO₂ is formed under different scanning spaces, and part of NiO is formed when the scanning space is 1μm. At the same time, it is found that the sample under the condition of 10 μm has the most excellent corrosion resistance and nanohardness. The nanohardness reaches 1303 ± 40 HV and the corrosion current density reaches 1.45 ± 0.1 × 10⁻⁹ A·cm⁻². Proper femtosecond laser treatment can effectively improve the surface strength and corrosion resistance of the NiTi alloys.