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A mathematical model is derived to predict the maximum speed of a focused laser beam in the laser cutting of thin materials. This model contains only two material parameters and is used to obtain an explicit relationship between the cutting speed and laser parameters. The model shows that there exists an optimal focal spot radius with which cutting speed is maximized for a given laser power. We compare the modeling results with experiments and find a good agreement after correcting laser fluence. This work is useful for the practical application of lasers in processing thin materials such as sheets and panels.

The concept for fabrication of waveguides by an in‐volume laser direct writing in single‐crystal silicon is explored using a nanosecond pulse laser. The key innovation of this technology relies on the generation of amorphous silicon, which has a higher refractive index than that of crystalline silicon. Herein, transmission electron microscopy (TEM) together with selected area electron diffraction (SAED) and high‐resolution TEM (HRTEM) characterizations are used to better understand the microstructural evolutions. TEM images reveal the core‐shell structures, while SAED patterns and HRTEM directly observe the presence of amorphous silicon in the core surrounded by a crystalline silicon shell. With a lower laser scanning speed, a higher density of defects yet less amorphous silicon is formed by laser direct writing.

Helical structures exhibit novel optical and mechanical properties and are commonly used in different fields such as metamaterials and microfluidics. A few methods exist for fabricating helical microstructures, but none of them has the throughput or flexibility required for patterning a large surface area with tunable pitch. In this paper, we report a method for fabricating helical structures with adjustable forms over large areas based on multiphoton polymerization (MPP) using single-exposure, three dimensionally structured, self-accelerating, axially tunable light fields. The light fields are generated as a superposition of high-order Bessel modes and have a closed-form expression relating the design of the phase mask to the rotation rate of the beam. The method is used to fabricate helices with different pitches and handedness in the material SU-8. Compared to point-by-point scanning, the method reported here can be used to reduce fabrication time by two orders of magnitude, paving the way for adopting MPP in many industrial applications.

Bursts of 16 femtosecond laser pulses are generated in a fourfold Michelson interferometer with a tunable delay and envelope. Solutions are given to solve the “forward problem” (bursts from a given parameter set) and “inverse problem” (obtain parameter set from a given burst). Three types of bursts are generated experimentally with envelopes suitable for applications in laser materials processing and the generation of terahertz radiation.