Micro‐fabrication and monitoring of three‐dimensional microstructures based on laser‐induced thermoplastic formation

This article reports a novel laser‐induced micro‐fabrication method and its monitoring system for three‐dimensional (3D) microstructures. The mechanism of the method is that a small zone of thermoplastic material melted by laser heating grows in liquid surrounding environment, solidifying into a convex microstructure, such as micro‐dot or micro‐pillar. A laser diode (808 nm) with maximum power output of 130 mW is used as power source, and a kind of paraffin mixed with stearic acid and paint serves as the thermoplastic material for 3D microstructure formation experiments. A light microscope system consisting of a charge‐coupled device (CCD) and a computer is utilized to realize real‐time observation of the micro‐fabricating process. The distribution of local temperature rise on material surface created by laser irradiation is simulated. The effects of liquid environment on microstructure formation have been theoretically analyzed and experimentally studied. Experiments are further carried out to investigate the relationship between laser spot and fabricated microstructures. The results indicate that the widths of micro‐dots or micro‐pillars are mostly determined by the size of focal spot, and their heights increase with the enlargement of laser power density. With this method, a micro‐dot array of Chinese characters meaning “China” has been successfully fabricated through computer programming. This method has the advantages of implementing direct, mask‐less, real‐time and inexpensive 3D microstructure fabrication. Therefore, it would be widely applied in the fields of micro/nano‐technology for practical fabrication of different kinds of 3D microstructures. Microsc. Res. Tech., 2009. © 2009 Wiley‐Liss, Inc.