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This article presents a novel approach for evaluating laser scribing quality through cross-section profiles generated from a three-dimensional optical profiler. Existing methods for assessing scribing quality only consider the width and depth of a scribe profile. The proposed method uses a cubic spline model for cross-section profiles. Two quality characteristics are proposed to assess scribing accuracy and consistency. Accuracy is measured by the ratio of the actual laser-scribed area to the target area (RA), which reflects the deviation from the desired profile. The mean square error (MSE) is a measure of how close each scribed cross-section under the same scribing conditions is to the fitted cubic spline model. Over 1370 cross-section profiles were generated under 171 scribing conditions. Two response surface polynomial models for RA and MSE were built with 18 scribing conditions with acceptable scribing depth and RA values. Both RA and MSE were considered simultaneously via contour plots. A scatter plot of RA and MSE was then used for Pareto optimization. It was found that the cross-sectional profile of a laser scribe could be accurately represented by a cubic spline model. A multivariate nonlinear regression model for RA and MSE identified pulse energy and repetition rate as the two dominant laser parameters. A Pareto optimization analysis further established a Pareto front, where the best compromised solution could be found. 

The nature of structural changes of nanosecond laser modification inside silicon is investigated. Raman spectroscopy and transmission electron microscopy measurements of cross sections of the modified channels reveal highly localized crystal deformation. Raman spectroscopy measurements prove the existence of amorphous silicon inside nanosecond laser induced modifications, and the percentage of amorphous silicon is calculated based on the Raman spectrum. For the first time, the high-resolution transmission electron microscopy images directly show the appearance of amorphous silicon inside nanosecond laser induced modifications, which corroborates the indirect measurements from Raman spectroscopy. The laser modified channel consists of a small amount of amorphous silicon embedded in a disturbed crystal structure accompanied by strain. This finding may explain the origin of the positive refractive index change associated with the written channels that may serve as optical waveguides. 

The development of thin-film photovoltaics has emerged as a promising solution to the global energy crisis within the field of solar cell technology. However, transitioning from laboratory scale to large-area solar cells requires precise and high-quality scribes to achieve the required voltage and reduce ohmic losses. Laser scribing has shown great potential in preserving efficiency by minimizing the drop in geometrical fill factor, resistive losses, and shunt formation. However, due to the laser induced photothermal effects, various defects can initiate and impact the quality of scribed grooves and weaken the module’s efficiency. In this regard, much research has been conducted to analyze the geometrical fill factor, surface integrity, and electrical performance of the laser scribes to reach higher power conversion efficiencies. This comprehensive review of laser scribing of photovoltaic solar thin films pivots on scribe quality and analyzes the critical factors and challenges affecting the efficiency and reliability of the scribing process. This review also covers the latest developments in using laser systems, parameters, and techniques for patterning various types of solar thin films to identify the optimized laser ablation condition. Furthermore, potential research directions for future investigations at improving the quality and performance of thin film laser scribing are suggested. 

Abstract The 3D freeze printing (3DFP) of nanocellulose aerogels are demonstrated with large‐scale aligned pore orientations as a sustainable alternative to current acoustical materials. In contrast with the unidirectional pore network orientations obtained from current 3DFP techniques, a bidirectional orientation is achieved by using an inhomogeneous printing substrate to alter the thermal gradient within the print volume. The microstructural morphology shows that bidirectional printing results in a 2D pore orientation, with comparatively thinner pore walls and larger pore widths. Acoustic measurements reveal that altering the pore network characteristics significantly affects the acoustical behavior of the printed CNC aerogels; the wider pores allow the bidirectional CNC aerogels to provide higher sound absorption performance at lower frequencies than the unidirectional samples. Notably, both 3D Freeze printed CNC aerogels provide substantially higher sound transmission loss performance as compared to current acoustical materials. The unidirectional pore structure results in CNC aerogels with higher stiffness and improved energy absorption performance, with both 3D freeze printed CNC aerogels outperforming other CNC aerogel materials in their stiffness‐to‐density ratios. The ability to simultaneously control their pore orientation and macrostructural geometry paves the way for printing complex shaped CNC aerogel structures for multifunctional noise control applications. 

Owing to the opaque nature of the laminated structures, traditional high-speed optical camera cannot be used to detect the dynamic process of sub-surface deformation. In this article, we report a study of using high speed X-ray imaging to study the high strain rate deformation in laminated Al structures. We used a Kolsky bar apparatus to apply dynamic compression and a high-speed synchrotron X-ray phase contrast imaging (PCI) setup to conduct the in situ X-ray imaging study. The in situ X-ray imaging captures the shock wave propagation in the laminated structures. After shock compression, we characterized the microstructures by using transmission electron microscopy (TEM), which demonstrates an increase of dislocation density. The micro-pillar compression tests show that the yield strength at 0.2% offset of laminated Al-graphene composite has a significant increase of 67%, from 30 to 50 MPa, compared to laminate Al after shock loading. 

We demonstrate, for the first time, the direct writing of curved optical waveguides in monocrystalline silicon with curve radii from 2 mm to 6 cm. The bending loss of the curved waveguides is measured and a good agreement with theoretical values is found. Raman spectroscopy measurements suggest the formation of inhomogeneous amorphous and polycrystalline phases in the laser-modified region. This direct laser-writing method may advance fabrication capabilities for integrated 3D silicon photonic devices.