Femtosecond laser micromachining has emerged in recent years as a new technique for micro/nano structure fabrication because of its applicability to virtually all kinds of materials in an easy one-step process that is scalable. In the past, much research on femtosecond laser micromachining was carried out to understand the complex ablation mechanism, whereas recent works are mostly concerned with the fabrication of surface structures because of their numerous possible applications. The state-of-the-art knowledge on the fabrication of these structures on metals with direct femtosecond laser micromachining is reviewed in this article. The effect of various parameters, such as fluence, number of pulses, laser beam polarization, wavelength, incident angle, scan velocity, number of scans, and environment, on the formation of different structures is discussed in detail wherever possible. Furthermore, a guideline for surface structures optimization is provided. The authors’ experimental work on laser-inscribed regular pattern fabrication is presented to give a complete picture of micromachining processes. Finally, possible applications of laser-machined surface structures in different fields are briefly reviewed.

Hierarchical laser-patterned surfaces were tested for their drag reduction abilities. A tertiary level of surface roughness which supports stable Cassie wetting was achieved on the patterned copper samples by laser-scanning multiple times. The laser-fabricated micro/nano structures sustained the shear stress in liquid flow. A rheometer setup was used to measure the drag reduction abilities in term of slip lengths on eight different samples. A considerable increase in slip length (111% on a grate sample) was observed on these surfaces compared to the slip length predictions from the theoretical and the experimental models for the non-hierarchical surfaces. The increase in slip lengths was correlated to the secondary level of roughness observed on the patterned samples. The drag reduction abilities of three different arrangements of the surface features were also compared: posts in a square lattice, parallel grates, and posts in a hexagonal lattice. Although the latter facilitates a stable Cassie state, it nevertheless resulted in a lower normalized slip length compared to the other two arrangements at a similar solid fraction. Furthermore, we coated the laser-patterned surfaces with a silane to test the effect of surface chemistry on drag reduction. While the contact angles were surprisingly similar for both the non-silanized and the silanized samples, we observed higher slip lengths on the latter, which we were able to explain by measuring the respective penetration depths of the liquid–vapour interface between surface features.

Nature shows many examples of surfaces with extraordinary wettability, which can often be associated with particular air-trapping surface patterns. Here, robust non-wetting surfaces have been created by femtosecond laser ablation of polytetrafluoroethylene (PTFE). The laser-created surface structure resembles a forest of entangled fibers, which support structural superhydrophobicity even when the surface chemistry is changed by gold coating. SEM analysis showed that the degree of entanglement of hairs and the depth of the forest pattern correlates positively with accumulated laser fluence and can thus be influenced by altering various laser process parameters. The resulting fibrous surfaces exhibit a tremendous decrease in wettability compared to smooth PTFE surfaces; droplets impacting the virgin or gold coated PTFE forest do not wet the surface but bounce off. Exploratory bioadhesion experiments showed that the surfaces are truly air-trapping and do not support cell adhesion. Therewith, the created surfaces successfully mimic biological surfaces such as insect wings with robust anti-wetting behavior and potential for antiadhesive applications. In addition, the fabrication can be carried out in one process step, and our results clearly show the insensitivity of the resulting non-wetting behavior to variations in the process parameters, both of which make it a strong candidate for industrial applications.