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Abstract The superhydrophobicity of submerged surfaces typically pertains to the trapped air film at the liquid–solid interface, subject to wettability transitions from a Cassie–Baxter state to more unstable states that gradually collapse to high retention regimes, which are energetically more favorable. In this work, the dynamic evolution of those transient metastable states is correlated to the underwater acoustic performance of laser textured superhydrophobic surfaces, resolving the dependence of the ultrasound spectral response with the immersion time to capture the genuine contribution of the hierarchical subwavelength morphology, regardless of the air layer effects. Acoustic wave attenuation of the incident ultrasound energy is extensively quantified in transmission, accounting for instantaneous broadband sound blocking (>30 dB) within the spectral range 0.5–1.5 MHz. As a result of the air layer detachment with the immersion time, transmission coefficients increase accordingly, while acoustic fields in reflection unexpectedly evolve toward stealthiness and naïve acoustic camouflage, mostly ascribable to dissipative mechanisms at air layer interfaces. The intrinsic decay of the air layer effect is tentatively determined at different frequencies, since quantitative understanding of the transient lifetime governing underwater surface wettability is critical to design stable superhydrophobic character of laser induced subwavelength metastructures on the most promising acoustic materials – from eco‐friendly natural to artificial.

Inertial focusing-based Lab-on-Chip systems represent a promising technology for cell sorting in various applications, thanks to their alignment with the ASSURED criteria recommended by the World Health Organization: Affordable, Sensitive, Specific, User-friendly, Rapid and Robust, Equipment-free, and Delivered. Inertial focusing techniques using spiral microchannels offer a rapid, portable, and easy-to-prototype solution for cell sorting. Various microfluidic devices have been investigated in the literature to understand how hydrodynamic forces influence particle focusing in spiral microchannels. This is crucial for the effective prototyping of devices that allow for high-throughput and efficient filtration of particles of different sizes. However, a clear, comprehensive, and organized overview of current research in this area is lacking. This review aims to fill this gap by offering a thorough summary of the existing literature, thereby guiding future experimentation and facilitating the selection of spiral geometries and materials for cell sorting in microchannels. To this end, we begin with a detailed theoretical introduction to the physical mechanisms underlying particle separation in spiral microfluidic channels. We also dedicate a section to the materials and prototyping techniques most commonly used for spiral microchannels, highlighting and discussing their respective advantages and disadvantages. Subsequently, we provide a critical examination of the key details of inertial focusing across various cross-sections (rectangular, trapezoidal, triangular, hybrid) in spiral devices as reported in the literature.

Abstract Many devices and objects, from microelectronics to microfluidics, consist of parts made from dissimilar materials, such as different polymers, metals or semiconductors. Techniques for joining such hybrid micro-devices, generally, are based on gluing or thermal processes, which all present some drawbacks. For example, these methods are unable to control the size and shape of the bonded area, and present risks of deterioration and contamination of the substrates. Ultrashort laser bonding is a non-contact and flexible technique to precisely join similar and dissimilar materials, used both for joining polymers, and polymers to metallic substrates, but not yet for joining polymers to silicon. We report on direct transmission femtosecond laser bonding of poly(methyl methacrylate) (PMMA) and silicon. The laser process was performed by focusing ultrashort laser pulses at high repetition rate at the interface between the two materials through the PMMA upper layer. The PMMA-Si bond strength was evaluated as a function of different laser processing parameters. A simple, analytical, model was set up and used to determine the temperature of the PMMA during the bonding process. As a proof of concept, the femtosecond-laser bonding of a simple hybrid PMMA-Si microfluidic device has been successfully demonstrated through dynamic leakage tests.

Zinc oxide is a safe material for humans, with high biocompatibility and negligible cytotoxicity. Interestingly, it shows exceptional antimicrobial activity against bacteria, viruses, fungi, etc., especially when reduced to the nanometer size. As it is easily understandable, thanks to its properties, it is at the forefront of safe antimicrobials in this pandemic era. Besides, in the view of the 2022 European Green Deal announced by the European Commission, even science and nanotechnology are moving towards “greener” approaches to the synthesis of nanoparticles. Among them, biogenic ZnO nanoparticles have been extensively studied for their biological applications and environmental remediation. Plants, algae, fungi, yeast, etc., (which are composed of naturally occurring biomolecules) play, in biogenic processes, an active role in the formation of nanoparticles with distinct shapes and sizes. The present review targets the biogenic synthesis of ZnO nanoparticles, with a specific focus on their bioactive properties and antimicrobial application.

The modification of the surface topography at the micro- and nanoscale is a widely established as one of the best ways to engineering the surface of materials, to improve the tribological performances of materials in terms of load capacity and friction. The present paper reviews the state of the art on laser surface texturing by exploiting the technique of direct laser writing for tailoring the coefficient of friction, highlighting the effect of the textures’ arrangement on the lubricated conformal and non-conformal contact behavior.

Rapid prototyping methods for the design and fabrication of polymeric labs-on-a-chip are on the rise, as they allow high degrees of precision and flexibility. For example, a microfluidic platform may require an optimization phase in which it could be necessary to continuously modify the architecture and geometry; however, this is only possible if easy, controllable fabrication methods and low-cost materials are available. In this paper, we describe the realization process of a microfluidic tool, from the computer-aided design (CAD) to the proof-of-concept application as a capture device for circulating tumor cells (CTCs). The entire platform was realized in polymethyl methacrylate (PMMA), combining femtosecond (fs) laser and micromilling fabrication technologies. The multilayer device was assembled through a facile and low-cost solvent-assisted method. A serpentine microchannel was then directly biofunctionalized by immobilizing capture probes able to distinguish cancer from non-cancer cells without labeling. The low material costs, customizable methods, and biological application of the realized platform make it a suitable model for industrial exploitation and applications at the point of care.

Abstract In this work, we performed an experimental investigation supported by a theoretical analysis, to improve knowledge on the laser ablation of silicon with THz bursts of femtosecond laser pulses. Laser ablated craters have been created using 200 fs pulses at a wavelength of 1030 nm on silicon samples systematically varying the burst features and comparing to the normal pulse mode (NPM). Using bursts in general allowed reducing the thermal load to the material, however, at the expense of the ablation rate. The higher the number of pulses in the bursts and the lower the intra-burst frequency, the lower is the specific ablation rate. However, bursts at 2 THz led to a higher specific ablation rate compared to NPM, in a narrow window of parameters. Theoretical investigations based on the numerical solution of the density-dependent two temperature model revealed that lower lattice temperatures are reached with more pulses and lower intra-burst frequencies, thus supporting the experimental evidence of the lower thermal load in burst mode (BM). This is ascribed to the weaker transient drop of reflectivity, which suggests that with bursts less energy is transferred from the laser to the material. This also explains the trends of the specific ablation rates. Moreover, we found that two-photon absorption plays a fundamental role during BM processing in the THz frequency range.

Unlike other antimicrobial agents, Ag-based composites are stable and currently widely used as broad spectral additives, fighting microbial biofilms and other biological threats. The goal of the present study is to develop a green, multifunctional, and robust antibiofilm water-insoluble coating, inhibiting histamine-producing Lentilactobacillus parabuchneri biofilms. Herein, laser-ablated Ag NPs (L-Ag NPs) were incorporated into and onto a montmorillonite (MMT) surface layer with a simple wet chemical method, provided that the electrostatic interaction between L-Ag NPs and MMT clay led to the formation of L-Ag/MMT nanoantimicrobials (NAMs). The use of MMT support can facilitate handling Ag NPs in industrial applications. The Ag/MMT composite was characterized with transmission electron microscopy (TEM) and scanning electron microscopy (SEM), which confirmed the entrapment of L-Ag NPs into MMT clay. The surface chemical composition was assessed with X-ray photoelectron spectroscopy, proving that Ag NPs were in contact with and deposited onto the surface of MMT. The characteristic L-Ag/MMT band was investigated with UV–vis spectroscopy. Following that, the L-Ag/MMT composite was embedded into a biosafe water-insoluble beeswax agent with a spin coating technique. The antimicrobial ion release kinetic profile of the L-Ag/MMT/beeswax coating through an electrothermal atomic absorption spectroscopy (ETAAS) study supported the controlled release of Ag ions, reaching a plateau at 420 ± 80 nM, which is safe from the point of view of Ag toxicity. Microbial biofilm growth inhibition was assessed with real-time in situ Fourier transform infrared attenuated total reflection spectroscopy (FTIR-ATR) in a flow cell assembly over 32 h. The study was further supported by optical density (OD) measurements and SEM on bacteria incubated in the presence of the L-Ag/MMT/beeswax coating.

The possibility of fabricating micrometric pore size membranes is gaining great interest in many applications, from studying cell signaling, to filtration. Currently, many technologies are reported to fabricate such microsystems, the choice of which depends strictly on the substrate material and on the final application. Here, we demonstrate the capability with a single femtosecond laser source and experimental setup to fabricate micromembranes both on polymeric and multilayer metallic substrate, without the need for moulds, mask, and complex facilities. In particular, the flexibility of laser drilling was exploited to obtain microfilters with pore size of 8 and 18 µm in diameter, on metallic and polymeric substrate, respectively, and controlled distribution. For evaluating the possibility to use such laser-fabricated membranes into biological assay, their biocompatibility has been investigated. To this aim, as a proof of concept, we tested the two materials into viability tests. The culture of mammalian cells on these microfabricated membranes were studied showing their compatibility with cells.

Laser beam welding offers high productivity and relatively low heat input and is one key enabler for efficient manufacturing of sandwich constructions. However, the process is sensitive to how the laser beam is positioned with regards to the joint, and even a small deviation of the laser beam from the correct joint position (beam offset) can cause severe defects in the produced part. With tee joints, the joint is not visible from top side, therefore traditional seam tracking methods are not applicable since they rely on visual information of the joint. Hence, there is a need for a monitoring system that can give early detection of beam offsets and stop the process to avoid defects and reduce scrap. In this paper, a monitoring system using a spectrometer is suggested and the aim is to find correlations between the spectral emissions from the process and beam offsets. The spectrometer produces high dimensional data and it is not obvious how this is related to the beam offsets. A machine learning approach is therefore suggested to find these correlations. A multi-layer perceptron neural network (MLPNN), support vector machine (SVM), learning vector quantization (LVQ), logistic regression (LR), decision tree (DT) and random forest (RF) were evaluated as classifiers. Feature selection by using random forest and non-dominated sorting genetic algorithm II (NSGAII) was applied before feeding the data to the classifiers and the obtained results of the classifiers are compared subsequently. After testing different offsets, an accuracy of 94% was achieved for real-time detection of the laser beam deviations greater than 0.9 mm from the joint center-line.

In this work, a fast optical spectrometer was used to monitor the Directed Energy Deposition (DED) process, during the deposition of Alloy 718 samples with different laser power, thus different energy inputs into the material. Spectroscopic measurements revealed the presence of excited Cr I atoms in the plasma plume. The presence was more apparent for the samples characterized by higher energy input. The Cr depletion from these samples was confirmed by lower Cr content detected by Energy-Dispersive X-ray Spectroscopy (EDS) analysis. The samples were also characterized by higher oxidation and high-temperature corrosion rates in comparison to the samples produced with low energy input. These results prove the applicability of an optical emission spectroscopic system for monitoring DED to identify process conditions leading to compositional changes and variation in the quality of the built material. Keywords: spectroscopic system, Additive manufacturing, Directed energy deposition, Cr depletion, High-temperature corrosion

Oral cancer belongs to the group of head and neck cancers, and, despite its large diffusion, it suffers from low consideration in terms of prevention and early diagnosis. The main objective of the SMILE platform is the development of a low-cost device for oral cancer early screening with features of high sensitivity, specificity, and ease of use, with the aim of reaching a large audience of possible users and realizing real prevention of the disease. To achieve this goal, we realized two microfluidic devices exploiting low-cost materials and processes. They can be used in combination or alone to obtain on-chip sample preparation and/or detection of circulating tumor cells, selected as biomarkers of oral cancer. The realized devices are completely transparent with plug-and-play features, obtained thanks to a highly customized architecture which enables users to easily use them, with potential for a common use among physicians or dentists with minimal training.

Designing bioactive materials, with controlled metal ion release, exerting a significant biological action and associated to low toxicity for humans, is nowadays one of the most important challenges for our community. The most looked-for nanoantimicrobials are capable of releasing metal species with defined kinetic profiles, either by slowing down or inhibiting bacterial growth and pathogenic microorganism diffusion. In this study, laser ablation synthesis in solution (LASiS) has been used to produce bioactive Ag-based nanocolloids, in isopropyl alcohol, which can be used as water-insoluble nano-reservoirs in composite materials like poly(3-hydroxybutyrate-co-3-hydroxyvalerate). Infrared spectroscopy was used to evaluate the chemical state of pristine polymer and final composite material, thus providing useful information about synthesis processes, as well as storage and processing conditions. Transmission electron microscopy was exploited to study the morphology of nano-colloids, along with UV-Vis for bulk chemical characterization, highlighting the presence of spheroidal particles with average diameter around 12 nm. Electro-thermal atomic absorption spectroscopy was used to investigate metal ion release from Ag-modified products, showing a maximum release around 60 ppb, which ensures an efficient antimicrobial activity, being much lower than what recommended by health institutions. Analytical spectroscopy results were matched with bioactivity tests carried out on target microorganisms of food spoilage.

This study investigates the influence of resistive pre-heating of the feedstock wire (here called hot-wire) on the stability of laser-directed energy deposition of Duplex stainless steel. Data acquired online during depositions as well as metallographic investigations revealed the process characteristic and its stability window. The online data, such as electrical signals in the pre-heating circuit and images captured from side-view of the process interaction zone gave insight on the metal transfer between the molten wire and the melt pool. The results show that the characteristics of the process, like laser-wire and wire-melt pool interaction, vary depending on the level of the wire pre-heating. In addition, application of two independent energy sources, laser beam and electrical power, allows fine-tuning of the heat input and increases penetration depth, with little influence on the height and width of the beads. This allows for better process stability as well as elimination of lack of fusion defects. Electrical signals measured in the hot-wire circuit indicate the process stability such that the resistive pre-heating can be used for in-process monitoring. The conclusion is that the resistive pre-heating gives additional means for controlling the stability and the heat input of the laser-directed energy deposition.

We report on a one-step method for cutting 250-µm-thick quartz plates using highly focused ultrashort laser pulses with a duration of 200 fs and a wavelength of 1030 nm. We show that the repetition rate, the scan speed, the pulse overlap and the pulse energy directly influence the cutting process and quality. Therefore, a suitable choice of these parameters was necessary to get single-pass stealth dicing with neat and flat cut edges. The mechanism behind the stealth dicing process was ascribed to tensile stresses generated by the relaxation of the compressive stresses originated in the laser beam focal volume during irradiation in the bulk material. Such stresses produced micro-fractures whose controlled propagation along the laser beam path led to cutting of the samples.

The capability of isolating and sorting specific types of cells is crucial in life science, particularly for the early diagnosis of lethal diseases and monitoring of medical treatments. Among all the micro-fluidics techniques for cell sorting, inertial focusing combined with the laminar vortex technology is a powerful method to isolate cells from flowing samples in an efficient manner. This label-free method does not require any external force to be applied, and allows high throughput and continuous sample separation, thus offering a high filtration efficiency over a wide range of particle sizes. Although rather recent, this technology and its applications are rapidly growing, thanks to the development of new chip designs, the employment of new materials and microfabrication technologies. In this review, a comprehensive overview is provided on the most relevant works which employ inertial focusing and laminar vortex technology to sort particles. After briefly summarizing the other cells sorting techniques, highlighting their limitations, the physical mechanisms involved in particle trapping and sorting are described. Then, the materials and microfabrication methods used to implement this technology on miniaturized devices are illustrated. The most relevant evolution steps in the chips design are discussed, and their performances critically analyzed to suggest future developments of this technology.

In this paper we describe a novel spectroscopic closed loop control system capable of stabilizing the penetration depth during laser welding processes by controlling the laser power. Our novel approach is to analyze the optical emission from the laser generated plasma plume above the keyhole, to calculate its electron temperature as a process-monitoring signal. Laser power has been controlled by using a quantitative relationship between the penetration depth and the plasma electron temperature. The sensor is able to correlate in real time the difference between the measured electron temperature and its reference value for the requested penetration depth. Accordingly the closed loop system adjusts the power, thus maintaining the penetration depth.

Microinjection moulding combined with the use of removable inserts is one of the most promising manufacturing processes for microfluidic devices, such as lab-on-chip, that have the potential to revolutionize the healthcare and diagnosis systems. In this work, we have designed, fabricated and tested a compact and disposable plastic optical stretcher. To produce the mould inserts, two micro manufacturing technologies have been used. Micro electro discharge machining (µEDM) was used to reproduce the inverse of the capillary tube connection characterized by elevated aspect ratio. The high accuracy of femtosecond laser micromachining (FLM) was exploited to manufacture the insert with perfectly aligned microfluidic channels and fibre slots, facilitating the final composition of the optical manipulation device. The optical stretcher operation was tested using microbeads and red blood cells solutions. The prototype presented in this work demonstrates the feasibility of this approach, which should guarantee real mass production of ready-to-use lab-on-chip devices.

Silver nanoparticles (AgNPs) are well-known for their antimicrobial effects and several groups are proposing them as active agents to fight antimicrobial resistance. A wide variety of methods is available for nanoparticle synthesis, affording a broad spectrum of chemical and physical properties. In this work, we report on AgNPs produced by laser ablation synthesis in solution (LASiS), discussing the major features of this approach. Laser ablation synthesis is one of the best candidates, as compared to wet-chemical syntheses, for preparing Ag nano-antimicrobials. In fact, this method allows the preparation of stable Ag colloids in pure solvents without using either capping and stabilizing agents or reductants. LASiS produces AgNPs, which can be more suitable for medical and food-related applications where it is important to use non-toxic chemicals and materials for humans. In addition, laser ablation allows for achieving nanoparticles with different properties according to experimental laser parameters, thus influencing antibacterial mechanisms. However, the concentration obtained by laser-generated AgNP colloids is often low, and it is hard to implement them on an industrial scale. To obtain interesting concentrations for final applications, it is necessary to exploit high-energy lasers, which are quite expensive. In this review, we discuss the pros and cons of the use of laser ablation synthesis for the production of Ag antimicrobial colloids, taking into account applications in the food packaging field.

The plasma optical radiation emitted during CO2 laser welding of stainless steel samples has been detected with a Si-PIN photodiode and analyzed under different process conditions. The discrete wavelet transform (DWT) has been used to decompose the optical signal into various discrete series of sequences over different frequency bands. The results show that changes of the process settings may yield different signal features in the range of frequencies between 200 Hz and 30 kHz. Potential applications of this method to monitor in real time the laser welding processes are also discussed.

In this paper we report on the development of a sensor for real time monitoring of laser welding processes based on spectroscopic techniques. The system is based on the acquisition of the optical spectra emitted from the laser generated plasma plume and their use to implement an on-line algorithm for both the calculation of the plasma electron temperature and the analysis of the correlations between selected spectral lines. The sensor has been patented and it is currently available on the market.

We have introduced a new hybrid fabrication method for lab-on-a-chip devices through the combination of femtosecond laser micromachining and removable insert micro-injection molding. This method is particularly suited for the fast prototyping of new devices, while maintaining a competitive low cost. To demonstrate the effectiveness of our approach, we designed, fabricated, and tested a completely integrated flow cytometer coupled to a portable media device. The system operation was tested with fluorescent plastic micro-bead solutions ranging from 100 beads/μL to 500 beads/μL. We demonstrated that this hybrid lab-on-a-chip fabrication technology is suitable for producing low-cost and portable biological microsystems and for effectively bridging the gap between new device concepts and their mass production.

Femtosecond laser surface micro-texturing has emerged as a promising technology to enhance the tribological properties of different kinds of electromechanical devices. In this research paper, we have exploited the intrinsic flexibility and micrometric accuracy of femtosecond laser ablation to realize complex micro-structural modifications on the surface of a laboratory prototype of a steel thrust bearing (un-tapered) pad. The Bruggeman Texture Hydrodynamics theory (BTH) is employed for the design of the anisotropic and non-uniform texture maximizing the thrust load of the pad prototype. The preliminary experimental results, reported in this work, show that the non-uniform micro-texture largely affects the friction characteristics of the contact. In particular, in agreement with the BTH predictions, the tribo-system shows friction properties that are strongly sensitive to the direction of the sliding speed, as a consequence of the micro-fluid dynamics which are designed to occur only in a specific sliding direction. We suggest that the joint action of virtual prototyping (BTH lubrication theory) and ultrafast laser micro-prototyping can lead to unconventional and impressive results in terms of enhanced or tailored contact mechanics properties of the generic lubricated tribopair.

Copper-chitosan (Cu-CS) nanoantimicrobials are a novel class of bioactive agents, providing enhanced and synergistic efficiency in the prevention of biocontamination in several application fields, from food packaging to biomedical. Femtosecond laser pulses were here exploited to disrupt a Cu solid target immersed into aqueous acidic solutions containing different CS concentrations. After preparation, Cu-CS colloids were obtained by tuning both Cu/CS molar ratios and laser operating conditions. As prepared Cu-CS colloids were characterized by Fourier transform infrared spectroscopy (FTIR), to study copper complexation with the biopolymer. X-ray photoelectron spectroscopy (XPS) was used to elucidate the nanomaterials’ surface chemical composition and chemical speciation of the most representative elements. Transmission electron microscopy was used to characterize nanocolloids morphology. For all samples, ξ-potential measurements showed highly positive potentials, which could be correlated with the XPS information. The spectroscopic and morphological characterization herein presented outlines the characteristics of a technologically-relevant nanomaterial and provides evidence about the optimal synthesis parameters to produce almost monodisperse and properly-capped Cu nanophases, which combine in the same core-shell structure two renowned antibacterial agents.