Mild Fabrication of Polymeric Porous/Nonporous Micro‐Composite Structures via Enhancing the Photothermal Conversion of Ultrafast Laser

Abstract Localized foaming of polymers is promising to fabricate polymeric composite structures for applications in biomedical, aerospace, automotive, etc. However, the severe pyrolysis and carbonization of polymer chains during localized foaming may degrade the bulk strength. Herein, a mild localized foaming strategy is proposed to fabricate poly(lactic acid) (PLA) micro‐foams within dense PLA matrices using ultrafast lasers. The PLA substrates doped with graphene (Gr) and azodicarbonamide (AC) are developed for mild foaming. A picosecond laser is applied to pattern PLA micro‐foams on the PLA/Gr/AC substrates to fabricate porous/nonporous micro‐composite structures. The thermal behavior of the PLA/Gr/AC substrates is characterized to evaluate their capability in photothermal conversion and mild foaming during ultrafast laser pulses. To optimize the laser foaming process, the microstructure of the laser‐foamed PLA processed with different laser parameters is studied. It demonstrates that the oxidation of the functional groups dominates the side reactions on the PLA chains with slight variation in molecular weight during laser foaming, indicating that the PLA chains keep almost intact and mild localized foaming is realized. Furthermore, the developed technology is demonstrated for micro‐patterning and texturing, material toughness programming, and shape memory programming, showing promising applications for smart materials, metamaterials, micro‐robotics, and biological scaffolds.