Tackling the next steps in direct laser interference patterning: 3D-texturing and process control

Direct Laser Interference Patterning (DLIP) is a versatile technique for creating microstructures that mimic natural surfaces, offering significant potential for surface functionalization. This study explores DLIP's application on complex 3D geometries using advanced 4- and 5-axis systems and focuses on real-time process monitoring to enhance quality and repeatability. A novel machine platform with simultaneous translational and rotational capabilities, equipped with an extended interference volume, was employed. The process monitoring module, utilizing Acoustic Emissions (AE) captured by a MEMS microphone, enabled in-process adjustments to maintain homogeneity. Results demonstrate the strong correlation between acoustic emissions and surface texture characteristics, facilitating closed-loop control for improved consistency. This approach significantly reduced variability in structure depth and produced high-quality, uniform textures, demonstrating the potential of AE-based monitoring for advanced DLIP applications.