Controlling laser induced surface morphology is essential for developing specialized functional surfaces. This work presents novel, multi-scale periodic patterns with two-dimensional symmetry generated on stainless steel, polyimide and sapphire. The microstructures were realized by combining Direct Laser Interference Patterning with the generation of Laser Induced Periodic Surface Structures in a one-step process. An industrial, fiber femtosecond laser source emitting at 1030 nm with a pulse duration of 500 fs was utilized for the experiments. In the case of stainless steel, it was possible to create line-like or pillar-like surface patterns by rotating the polarization orientation with respect to the interference pattern. In the case of polyimide and sapphire, the absorption of the laser radiation was promoted by a multiphoton mechanism. In polyimide, grooves and pillars of several microns in depth were produced over an area much larger than the spot size. Finally, for sapphire, the simultaneous generation of interference-like pattern and laser induced periodic surface structures was realized. The results reported here provide valuable data on the feasibility to combine two state-of-the-art techniques with an industrial apparatus, to control the induced surface morphology.

We show, for the first time to our knowledge, the role the heat accumulation plays on the evolution of ultra-short pulse laser-induced surface structures morphology when varying fluence, the number of scans and the repetition rate from 100 kHz up to 2 MHz. We demonstrate how to tailor the size of micro-spikes from nearly ten microns to several tens of microns by a systematic variation of both fluence and overlap. We believe our results will contribute to an in deep understanding of the mechanisms underlying laser surface structuration at high repetition rates.

Direct laser interference patterning (DLIP) with ultrashort laser pulses (ULPs) represents a precise and fast technique to produce tailored periodic submicrometer structures on various materials. In this work, an experimental and theoretical approach is presented to investigate the fundamental mechanisms for the formation of unprecedented laser-induced topographies on stainless steel following proper combinations of DLIP with ULPs. The combined spatial and temporal shaping of the pulse increases the level of control over the structure while it brings insights into the structure formation process. The aim of DLIP is to determine the initial conditions of the laser-matter interaction by defining an ablated region while double ULPs are used to control the reorganization of the self-assembled laser-induced submicrometer sized structures by exploiting the interplay of different absorption and excitation levels coupled with the melt hydrodynamics induced by the first of the double pulses. A multiscale physical model is presented to correlate the interference period, polarization orientation, and number of incident pulses with the induced morphologies. Special emphasis is given to electron excitation, relaxation processes, and hydrodynamical effects that are crucial to the production of complex morphologies. Results are expected to derive knowledge of laser-matter interaction in combined DLIP and ULP conditions and enable enhanced fabrication capabilities of complex hierarchical submicrometer sized structures for a variety of applications.

We present a novel approach for tailoring the laser induced surface topography upon femtosecond (fs) pulsed laser irradiation. The method employs spatially controlled double fs laser pulses to actively regulate the hydrodynamic microfluidic motion of the melted layer that gives rise to the structures formation. The pulse train used, in particular, consists of a previously unexplored spatiotemporal intensity combination including one pulse with Gaussian and another with periodically modulated intensity distribution created by Direct Laser Interference Patterning (DLIP). The interpulse delay is appropriately chosen to reveal the contribution of the microfluidic melt flow, while it is found that the sequence of the Gaussian and DLIP pulses remarkably influences the surface profile attained. Results also demonstrate that both the spatial intensity of the double pulse and the effective number of pulses per irradiation spot can further be modulated to control the formation of complex surface morphologies. The underlying physical processes behind the complex patterns’ generation were interpreted in terms of a multiscale model combining electron excitation with melt hydrodynamics. We believe that this work can constitute a significant step forward towards producing laser induced surface structures on demand by tailoring the melt microfluidic phenomena.