Fabrication of Large Area Two and Three-Level Multiscale Structures with Multi-Functional Surface Properties using laser fabrication methods
Final Report Abstract
Functionalized surfaces can be obtained by fabricating deterministic or stochastic structures with features in the micrometer, submicrometer and nanometer range. Furthermore, significantly enhanced surface properties can be produced by using micrometer scaled features covered by nano- or sub-micrometer structures, which occurs typically in nature. In this framework, this project focuses on three main objectives (i) design and development of original laser fabrication techniques to produce textured surfaces with periodic patterns at the micro/nano level; (ii) development of in-situ control methods for indirect measurement of surface homogeneity and texture control; and (iii) to understand how to reach advanced surface properties based on these modifications. Hence, the fundamental objective is to achieve a comprehensive knowledge of laser processing techniques through each of the process stages, in order to generate high-performance laser-based methods for numerous applications in products of daily use. Within the project, an outstanding amount of knowledge was generated through the three main objectives mentioned above. We have been able to understand the relationship between topographical and chemical/physico-chemical properties with the purpose of tuning different surface functionalities. In particular, the influence of different pulse durations on chemical modifications induced on metallic surfaces as well as the relevance of the initial surface energy of polymer materials for tuning their wettability. In addition, inspired by nature, a large amount of hierarchical surface patterns was fabricated utilizing different approaches. In case of metallic materials (Ti, Steels, Aluminum), conventional laser technologies have been combining including Direct Laser Writing (DLW), Direct Laser Interference Patterning (DLIP) and Laser Induced Periodic Structures (LIPSS). Furthermore, the implementation of Polygon Scanner Technology was addressed using a high power ps-laser source, that permit to produce textured surfaces having some tens of micrometers, but also the fabrication of LIPSS at high throughput. In case of the replication methods, plate-to-plate and roll-to-roll technologies could be implemented. In all cases, the structures fabricated on the master (metallic stamps) could be successfully transferred to different polymer materials (PET, PMMA, PC). Regarding the innovative development of laser technology, a multiple laser platform was designed and built (including the development of new optical concepts). Also a new concept for a DLIP optics was developed. This optical setup (patented) permitted to initiate additional projects (also with industrial partners) at the chair. Additionally, an in-line monitoring system was developed, capable of indirectly provide valuable information about surface texture homogeneity as well as detecting defects in real time. This setup has been not only used for monitoring laser texturing of the metallic samples but also was integrated into the R2R hot-embossing system, permitting to characterize in real time the polymer foils being hot-embossed. Regarding the different functionalities addressed, it was possible to produce multi-functional surfaces with superhydrophobic, self-cleaning and ice-repellent properties on Al-substrates. Regarding tissue engineering, it was possible to produce textured Ti-surfaces with improved antibacterial and antifouling behavior, as well as higher mechanical stability allowing to reduce implant dental and bone failures cause by bacterial infections. In collaboration with different European partners, also hierarchical textured polymer foils have been implemented as substrate for organic solar cells, allowing to significantly improve their efficiency. In addition, polymer foils having controlled spreading behavior for oils were developed. Last but not least, to expand laser processing methods to new materials, hot embossing methods have been applied to transfer the topography of metal templates to polymer substrates. This allows the texture of laser sensitive materials as biopolymers, light sensitive polymers or soft-matter materials. Textured polymer foils out of PMMA were also implemented as optical diffusers (e.g. for controlling spreading of LED light). This worthy research work has generated an impressive amount of publications. In total 54 research papers were published, 26 in peer-reviewed journals (other 5 are in preparation) as well as 28 as conference proceeding papers. Furthermore, the obtained results were presented in 78 contributions (as talks or poster presentations) at high-level national and international conferences. In addition to formal outreach activities, significant efforts have been addressed to reach non-specialist audiences, such as several press releases, short videos posted on social networks including Facebook, LinkedIn, Instagram and Twitter. An interview also broadcast on national German radio (MDR, Mitteldeutscher Eundfunk) and an article was published in the BILD newspaper. In addition, numerous students at different levels (bachelor, master and PhD) have actively participate in this project. In conclusion, the project “Fabrication of large-area, two- and three-level multiscale structures with multifunctional surface properties using laser-based methods” permitted an extreme significant progress in the field of laser-based surface functionalization, laser-material beam interaction and surface functionalization, allowing new innovative applications and setting a new benchmark for future research in advanced material sciences.
Publications
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Fabrication of superhydrophobic and ice-repellent surfaces on pure aluminium using single and multiscaled periodic textures. Scientific Reports, 9(1).
Milles, Stephan; Soldera, Marcos; Voisiat, Bogdan & Lasagni, Andrés F.
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Multiple method micromachining laser platform for fabricating anti-counterfeit elements with multiple-scaled features. Optics & Laser Technology, 115, 465-476.
Teutoburg-Weiss, Sascha; Sonntag, Frank; Günther, Katja & Lasagni, Andrés Fabián
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Characterization of self-cleaning properties on superhydrophobic aluminum surfaces fabricated by direct laser writing and direct laser interference patterning. Applied Surface Science, 525, 146518.
Milles, Stephan; Soldera, Marcos; Kuntze, Thomas & Lasagni, Andrés Fabián
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Prediction of Optimum Process Parameters Fabricated by Direct Laser Interference Patterning Based on Central Composite Design. Materials, 13(18), 4101.
El-Khoury, Mikhael; Voisiat, Bogdan; Kunze, Tim & Lasagni, Andrés Fabián
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Hybrid processing of bearing steel by combining Direct Laser Interference Patterning and laser hardening for wear resistance applications. Materials Letters, 303, 130284.
El-Khoury, Mikhael; Seifert, Marko; Bretschneider, Sven; Zawischa, Martin; Steege, Tobias; Alamri, Sabri; Fabián, Lasagni Andrés & Kunze, Tim
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Wetting Properties of Aluminium Surface Structures Fabricated Using Direct Laser Interference Patterning with Picosecond and Femtosecond Pulses. Journal of Laser Micro/Nanoengineering.
Milles, S. et al.
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PMMA Optical Diffusers with Hierarchical Surface Structures Imprinted by Hot Embossing of Laser‐Textured Stainless Steel. Advanced Optical Materials, 11(3).
Bouchard, Felix; Soldera, Marcos & Lasagni, Andrés Fabián
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Structural colors with embedded anti-counterfeit features fabricated by laser-based methods. Optics & Laser Technology, 151, 108012.
Teutoburg-Weiss, Sascha; Soldera, Marcos; Bouchard, Felix; Kreß, Joshua; Vaynzof, Yana & Lasagni, Andrés Fabián
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Utilizing a Diffractive Focus Beam Shaper to Enhance Pattern Uniformity and Process Throughput during Direct Laser Interference Patterning. Materials, 15(2), 591.
El-Khoury, Mikhael; Voisiat, Bogdan; Kunze, Tim & Lasagni, Andrés Fabián
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Compact Optical System Based on Scatterometry for Off-Line and Real-Time Monitoring of Surface Micropatterning Processes. Optics, 4(1), 198-213.
Soldera, Marcos; Teutoburg-Weiss, Sascha; Schröder, Nikolai; Voisiat, Bogdan & Lasagni, Andrés Fabián
