Ultrafast laser stabilization by nonlinear absorption for enhanced-precision material processing.

Using ultrafast lasers, sub-diffraction features can be produced thanks to the threshold-based response of materials to the local beam fluence. In practice, Gaussian beams with peak fluence near the modification threshold lead to high-resolution. However, this conflicts with reliability as the process becomes increasingly sensitive to pulse-to-pulse energy fluctuations. Using nonlinear absorption in a ZnS crystal, we demonstrate a passive extra-cavity energy stabilization method in a femtosecond laser material machining configuration. Processing precision and repeatability are enhanced as evidenced by highly reliable amorphous features produced on silicon with sizes ten times smaller than the spot size, becoming a practical solution for high-precision manufacturing applications.

Spraying dynamics in continuous wave laser printing of conductive inks.

Laser-induced forward transfer (LIFT), though usually associated with pulsed lasers, has been recently shown to be feasible for printing liquid inks with continuous wave (CW) lasers. This is remarkable not only because of the advantages that the new approach presents in terms of cost, but also because of the surprising transfer dynamics associated with it. In this work we carry out a study of CW-LIFT aimed at understanding the new transfer dynamics and its correlation with the printing outcomes. The CW-LIFT of lines of Ag ink at different laser powers and scan speeds revealed a range of conditions that allowed printing conductive lines with good electrical properties. A fast-imaging study showed that liquid ejection corresponds to a spraying behavior completely different from the jetting characteristic of pulsed LIFT. We attribute the spray to pool-boiling in the donor film, in which bursting bubbles are responsible for liquid ejection in the form of projected droplets. The droplet motion is then modeled as the free fall of rigid spheres in a viscous medium, in good agreement with experimental observations. Finally, thermo-capillary flow in the donor film allows understanding the evolution of the morphology of the printed lines with laser power and scan speed.

Low-Cost Fabrication of Printed Electronics Devices through Continuous Wave Laser-Induced Forward Transfer.

Laser-induced forward transfer (LIFT) is a direct-writing technique that allows printing inks from a liquid film in a similar way to inkjet printing but with fewer limitations concerning ink viscosity and loading particle size. In this work, we prove that liquid inks can be printed through LIFT by using continuous wave (CW) instead of pulsed lasers, which allows a substantial reduction in the cost of the printing system. Through the fabrication of a functional circuit on both rigid and flexible substrates (plastic and paper), we provide a proof-of-concept that demonstrates the versatility of the technique for printed electronics applications.