Functionalization of freeform curved surfaces by shaped femtosecond laser pulses in the propagation axis

Abstract

With ultrashort pulse durations and ultrahigh peak intensities, ultrafast lasers can create different types of micro/nano-structures to functionalize the processed surface with new properties. However, the applications of this method on freeform surfaces are still limited by the short length of a laser focusing spot and complex control of the 3D moving trajectory in the fabrication process. In this paper, we overcome this problem by shaping the on-axis intensity along the propagation axis using the spatial light modulator. By designing the phase mask, we increased the length of the stable-intensity zone (intensity fluctuation < 10%) by more than 3 times compared to that of an unshaped Bessel beam. The energy deposition was also optimized to be less than 2% fluctuation based on simulations. Using this method, we fabricated micro/nano structures on 3D surfaces at different fluences and demonstrated various properties including colorization, anti-reflection, and hydrophobicity in large height range. We demonstrated the applications of the proposed method in creating hydrophobicity on complex freeform syringe tip surfaces. This improved the minimum manipulatable volume of a liquid droplet to 2 times smaller compared with untreated syringe, thus greatly extending its performance for micro-droplet manipulation. This method offers an alternative approach for reliable and affordable freeform curved-surface processing.