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Ultrafast laser processing of zirconia/alumina nanocomposite ceramics, the current gold standard material for ceramic bearing components in orthopedics, was investigated. Instead of considering the substrate as a homogeneous material, as commonly assumed in laser micromachining, the damage behavior of different phases around the laser ablation threshold upon ultrafast laser irradiation was investigated. Under appropriate experimental conditions, the zirconia phase was selectively ablated while the alumina phase remained intact. The origin of this selective ablation behavior and its relationship with the material band gaps were discussed. Due to the nonlinear absorption mechanisms under ultrafast laser irradiation, the zirconia phase, with its band gap of 5.8 eV, can absorb more laser energy than the alumina phase which has a larger band gap of 8.8 eV. The negligible heat diffusion length ensures that the absorbed laser energy remains confined in the individual phases, leading to the selective ablation of zirconia phase under the given laser fluence. Based on this observation, an ultrafast laser selective phase removal method which can be used to modify the surface composition of nanocomposite materials consisting of phases with different band gaps was proposed.

Lenticular lenses are widely used in the three-dimensional display industry. Conventional lenticular lens components are made of plastics that have low thermal stability. An alternative is to use glass to replace plastic as the lenticular lens component material. Single crystal silicon is often used as the mold material in the precision glass molding process. It is, however, difficult to fabricate a lenticular lens silicon mold that has a large feature size compared to the critical depth of cut of silicon. In order to solve the problems of machining lenticular lens silicon molds using the conventional diamond cutting method, such as low machining efficiency and severe tool wear, a hybrid machining method that combined laser ablation and diamond cutting was proposed. A feasibility study was performed to investigate the possibility of using this method to fabricate a lenticular lens silicon mold. The influence of the laser parameters and machining parameters on the machining performance was investigated systematically. The experimental results indicated that this hybrid machining method could be a possible method for manufacturing lenticular lens silicon molds or other similar microstructures.

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