We report on a new, single-step and scalable method to fabricate highly ordered, multi-directional and complex surface structures that mimic the unique morphological features of certain species found in nature. Biomimetic surface structuring was realized by exploiting the unique and versatile angular profile and the electric field symmetry of cylindrical vector (CV) femtosecond (fs) laser beams. It is shown that, highly controllable, periodic structures exhibiting sizes at nano-, micro- and dual- micro/nano scales can be directly written on Ni upon line and large area scanning with radial and azimuthal polarization beams. Depending on the irradiation conditions, new complex multi-directional nanostructures, inspired by the Shark’s skin morphology, as well as superhydrophobic dual-scale structures mimicking the Lotus’ leaf water repellent properties can be attained. It is concluded that the versatility and features variations of structures formed is by far superior to those obtained via laser processing with linearly polarized beams. More important, by exploiting the capabilities offered by fs CV fields, the present technique can be further extended to fabricate even more complex and unconventional structures. We believe that our approach provides a new concept in laser materials processing, which can be further exploited for expanding the breadth and novelty of applications.

The significance of the magnitude of the Prandtl number of a fluid in the propagation direction of induced convection rolls is elucidated. Specifically, we report on the physical mechanism to account for the formation and orientation of previously unexplored supra-wavelength periodic surface structures in dielectrics, following melting and subsequent capillary effects induced upon irradiation with ultrashort laser pulses. Counterintuitively, it is found that such structures exhibit periodicities, which are markedly, even multiple times, higher than the laser excitation wavelength. It turns out that the extent to which the hydrothermal waves relax depends upon the laser beam energy, produced electron densities upon excitation with femtosecond pulsed lasers, the magnitude of the induced initial local roll disturbances, and the magnitude of the Prandtl number with direct consequences on the orientation and size of the induced structures. It is envisaged that this elucidation may be useful for the interpretation of similar, albeit large-scale periodic or quasiperiodic structures formed in other natural systems due to thermal gradients, while it can also be of great importance for potential applications in biomimetics.

We report on the morphological effects induced by the inhomogeneous absorption of radially polarized femtosecond laser irradiation of nickel (Ni) in sub-ablation conditions. A theoretical prediction of the morphology profile is performed, and the role of surface plasmon excitation in the production of self-formed periodic ripple structures is evaluated. Results indicate a smaller periodicity of the ripples profile compared to that attained under linearly polarized irradiation conditions. A combined hydrodynamical and thermoelastic model is presented in laser beam conditions that lead to material melting. The simulation results are presented to be in good agreement with the experimental findings. The ability to control the size of the morphological changes via modulating the beam polarization may provide an additional route for controlling and optimizing the outcome of laser micro-processing.