Nanosecond laser processing of common industrial polymers: surface characterization and morphological changes

• Nd: YAG laser irradiation (λ ≈ 1064 nm) was systematically studied on five industrial polymers: PS, PVC, PMMA, PET, and PP. • Distinct surface features such as craters, ripple, debris, and heat-affected zone (HAZ) were observed by optical and SEM analysis. • Laser exposure induced chemical modifications and new functional groups, enhancing optical absorption and infrared transmission. • A significant reduction in optical band gap and a polynomial relation between crater depth, HAZ, and thermal conductivity were established. • Controlled surface structuring shows potential of Nd: YAG laser processing for optoelectronic and microelectronic device fabrication. The impact of Nd: YAG laser irradiation, with a wavelength of ∼1064 nm under ambient air conditions, was systematically investigated on five widely used industrial polymers: polystyrene (PS), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), and polypropylene (PP). The objective is to induce optical, structural, and morphological changes that could enhance the polymer’s suitability for applications in photoelectronic and microelectronics. Characterization using optical microscopy, scanning electron microscopy (SEM), attenuated total reflectance fourier transform infrared spectroscopy (ATR-FTIR), and UV–VIS spectroscopy revealed substantial surface modifications, including crater formation, hydrodynamic sputtering, ripple patterns, debris deposition, and heat-affected zones (HAZ). Specifically, PS, PVC, and PET exhibited enhanced morphology and optical absorption, attributed to laser-induced defects and the generation of novel functional groups inside the polymer matrix. Laser treatment also modified the chemical structure of the polymers, increasing infrared transmission and significantly reducing the optical band gap. A polynomial relationship was identified between crater depth, the extent of the heat-affected zone, and the thermal conductivity of these polymers. This finding demonstrates the effective use of Nd:YAG lasers for precise and selective material removal, enabling the creation of intricate surface patterns. Such control over surface structuring is particularly valuable for advanced applications in the fabrication of optoelectronic and microelectronic devices.