Cross-scale high-efficiency fabrication method for functional structural units on rotational curved surfaces

To address the challenges of low efficiency and insufficient accuracy in fabricating functional microstructures on rotational curved surfaces, this study proposes an automated partitioned laser processing strategy. The method integrates a five-axis CNC platform with a dynamic beam-focusing module. Through geometric modeling, microstructure arrays are automatically divided according to the maximum allowable processing width, and the corresponding centroid coordinates are transformed into synchronized multi-axis trajectories. Experiments conducted on a self-developed machining platform demonstrate an efficiency improvement of approximately 80% compared with conventional sequential processing, while maintaining high dimensional accuracy and surface quality. Furthermore, electromagnetic performance measurements confirm that the fabricated structures exhibit stable band-pass transmission characteristics within the 25-36 GHz range. The proposed strategy enables high-throughput fabrication of cross-scale functional units on complex rotational surfaces and establishes a robust framework extendable to arbitrary freeform surface manufacturing.