Laser Metal Printing from Nanoparticles Prepared by a Gas Aggregation Source

This study demonstrates the use of nanoparticles prepared by a gas aggregation source for fabricating structures by combining laser sintering and ablation. At first, the morphology and optical properties of prepared nanoparticle coatings were characterized. Then, the response of coatings to laser irradiation at different powers or exposure times was studied by in situ time-of-flight mass spectrometry, followed by scanning electron microscopy measurements of the resulting structures. By comparing the numbers of detected Ag ions, that were ablated and desorbed, with changes in morphology after irradiation, the optimum conditions for laser sintering and ablation of Ag nanoparticle coatings were found. As a proof of concept we fabricated micromirrors from sintered metal, microwires from both sintered metal and interconnected nanoparticles, and arbitrary metallic bulky or nanoparticle patterns. Vacuum compatibility and the possibility of fabrication of both metallic and nanoparticle structures in one step predetermines applications of developed method in electronics or sensing.