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<p>Ultrashort pulsed (USP) lasers provide unparalleled precision in surface structuring, enabling controlled ablation with minimal thermal damage to materials. In this study, the femtosecond laser ablation characteristics of polyimide (PI), polyetherimide (PEI) and polycarbonate (PC) were investigated. By systematically varying fluence, the regimes of photochemical-dominated ablation that are optimal for surface structuring were identified. PI was selected for detailed exploration in scanned laser ablation and 3D surface structuring due to its superior ablation behaviour under these conditions. This study quantified the effects of pulse overlap, fluence, and heat accumulation on ablation rate and depth. This revealed that pulse and line overlaps influence ablation efficiency, even when the effective number of laser pulses is held constant. The differences in heat dissipation between pulse-to-pulse and scan-to-scan interactions were shown to modulate material removal, with higher overlaps leading to increased heat accumulation and higher ablation rates. The scanned ablation trends were further utilised to fabricate microfluidic stamp features precisely, such as a concentration gradient generator (CGG) structure. Finally, accelerated laser structuring was demonstrated by increasing the pulse repetition rate from 100&#xa0;kHz to 1000&#xa0;kHz, reducing processing time by up to 90% with minimal compromise to dimensional accuracy or surface quality. Overall, this work establishes a comprehensive framework for understanding and optimising USP laser-material interactions in PI for precision 3D structuring. The methodology, while demonstrated on PI, is broadly applicable to other polymeric materials, providing a valuable toolset for advancing high-resolution laser micromachining in diverse applications.</p>

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A Fundamental Approach to High-Precision 3D Microstructuring of High-Performance Polymers with Femtosecond Lasers

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年7月11日

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  • Pieter Daniël Haasbroek,
  • Armin Stumpp,
  • Ronald Holtz,
  • Per Magnus Kristiansen

摘要

Ultrashort pulsed (USP) lasers provide unparalleled precision in surface structuring, enabling controlled ablation with minimal thermal damage to materials. In this study, the femtosecond laser ablation characteristics of polyimide (PI), polyetherimide (PEI) and polycarbonate (PC) were investigated. By systematically varying fluence, the regimes of photochemical-dominated ablation that are optimal for surface structuring were identified. PI was selected for detailed exploration in scanned laser ablation and 3D surface structuring due to its superior ablation behaviour under these conditions. This study quantified the effects of pulse overlap, fluence, and heat accumulation on ablation rate and depth. This revealed that pulse and line overlaps influence ablation efficiency, even when the effective number of laser pulses is held constant. The differences in heat dissipation between pulse-to-pulse and scan-to-scan interactions were shown to modulate material removal, with higher overlaps leading to increased heat accumulation and higher ablation rates. The scanned ablation trends were further utilised to fabricate microfluidic stamp features precisely, such as a concentration gradient generator (CGG) structure. Finally, accelerated laser structuring was demonstrated by increasing the pulse repetition rate from 100 kHz to 1000 kHz, reducing processing time by up to 90% with minimal compromise to dimensional accuracy or surface quality. Overall, this work establishes a comprehensive framework for understanding and optimising USP laser-material interactions in PI for precision 3D structuring. The methodology, while demonstrated on PI, is broadly applicable to other polymeric materials, providing a valuable toolset for advancing high-resolution laser micromachining in diverse applications.