A systematic review of micro-texture formation based on milling: from mechanism, existing techniques, characterization to typical applications

Milling-based micro-texturing is an emerging technique that employs mechanical milling to create precise and flexible surface patterns, enabling controlled surface property modulation. With high precision, controllability, repeatability, and mass production, it finds extensive applications in optics, biomedical engineering, mechanical engineering, and among others. Herein, this paper systematically summarizes the key contents of micro-texturing technology from the perspective of mechanical milling for the first time. Firstly, the surface texture generation mechanisms are systematically described, encompassing milling forces modeling, texture formation process, and size effect. Secondly, the importance of tool selection and manufacturing in micro-milling is briefly addressed, followed by a detailed classification and comparison of existing milling-based micro-texturing techniques for metallic and non-metallic materials. Subsequently, the design criteria of surface micro-texturing, methods for characterizing its performance, and typical applications of this technology are summarized in detail. Finally, a brief summary and outlook for future work are delineated. This research is expected to facilitate the enhancement of surface performance, the development of functional materials, and the exploration of novel applications in response to ultra-precision manufacturing demands.