Optimizing two-photon polymerization for rapid and high-resolution prototyping of low-friction microtextured surfaces

Low-friction surfaces enhance performance across various sectors, such as boosting fuel efficiency in transportation and augmenting precision, safety, and comfort in medical devices. Given these benefits, there is a pressing need to investigate how the geometric characteristics of microtextured surfaces can effectively reduce friction, a process that demands precise geometric control. This study explores the application of Two-Photon Polymerization (TPP) as a high-resolution additive manufacturing technique for prototyping microtextured surfaces used in friction studies. TPP’s ability to create precise microstructures makes it an ideal tool for understanding the impact of geometrical factors on friction. However, a significant trade-off exists between print time and quality, particularly for large samples. The TPP parameters, including laser power, scan speed, hatch, and slice distances, were fine-tuned to cater to friction application and achieve a balance between resolution and efficiency. A hybrid fill mode combining solid, shell and scaffold printing was developed to reduce print time while maintaining surface integrity. Friction tests demonstrated that the TPP-printed microdimpled samples effectively reduced friction, highlighting the potential of TPP as a prototyping tool for tribological applications.