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Cross-scale high-efficiency fabrication method for functional structural units on rotational curved surfaces.
Optics Express
|May 4, 2026
Summary
This study introduces an automated laser processing method for creating microstructures on curved surfaces. The strategy significantly boosts fabrication efficiency by 80% while ensuring high accuracy and stable electromagnetic performance.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Optics
Background:
- Fabricating microstructures on curved surfaces faces challenges in efficiency and accuracy.
- Existing methods struggle with complex geometries and high-throughput demands.
Purpose of the Study:
- To develop an automated partitioned laser processing strategy for efficient and accurate microstructure fabrication on rotational curved surfaces.
- To enhance the manufacturing of functional microstructures for electromagnetic applications.
Main Methods:
- Integration of a five-axis CNC platform with a dynamic beam-focusing module.
- Automated geometric modeling for partitioning microstructure arrays based on processing width.
- Transformation of centroid coordinates into synchronized multi-axis trajectories.
Main Results:
- Achieved an approximate 80% improvement in fabrication efficiency compared to conventional sequential processing.
- Maintained high dimensional accuracy and excellent surface quality of fabricated microstructures.
- Demonstrated stable band-pass transmission characteristics (25-36 GHz) for fabricated structures.
Conclusions:
- The proposed automated partitioned laser processing strategy enables high-throughput fabrication on complex rotational surfaces.
- This method provides a robust framework for manufacturing functional units on arbitrary freeform surfaces.
- The strategy overcomes limitations in efficiency and accuracy for microfabrication on curved substrates.
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