Laser Molding in Polymeric Materials Using Femto-Second Laser Pulse and Replication via Electroforming

The upheaval structure on the surface of polymer induced by the irradiation of a near-infrared (NIR) femto-second laser pulse in polymer bulk was investigated. Copolymers, such as poly(acrylonitrile-styrene) (AS) and poly(acrylonitrilebutadiene-styrene-methyl methacrylate) (ABSM) produced upheaval structures with a flattop just like the crater of a volcano, whereas homopolymers with relatively high glass transition temperature (Tg), such as polycarbonate (PC) and polyether imide (PEI) were more often formed a bell-shaped upheaval structure. A micro-lens effect was observed for the bell-shaped upheaval structure, but that effect was not observed in the case of copolymers with a flattop structure. Replication of the bell-shaped upheaval structure in PC was carried out by electroforming (non-electrolytic plating of Ni and the following electrolytic plating of Ni) and potting approximately 30 wt% THF solution of AS copolymer. A micro-scale bell-shaped upheaval structure in PC induced by a laser pulse was replicated using a Ni mother mold with suitable precision, and the replicated bell-shaped structure also showed a micro-lens effect.