Cutting edge

A technique that uses a laser beam to burn micrometre-fine patterns into complex-shaped component surfaces promises to be cheaper and more environmentally friendly than traditional etching methods.

For years etching has been the way to create fine microstructures on component surfaces to give them added cosmetic or performance properties. Plastic dashboards, for example, can be made to look like leather and sharkskin ribs on an aircraft's fuselage reduce air resistance.

Although lasers have been used for a long time to structure flat surfaces, etching techniques have been the only choice for 3D components of complex shape.

'Many manufacturers want to substitute etching processes because they are very cost intensive and use chemicals that have to be disposed of later,' said Sascha Bausch, the lead developer of the laser system at the

in Aache, Germany. 'We thought this process might be improved by using a laser.'

Bausch's R&D team recently launched a laser that can burn microstructures into free-form surfaces. With the help of industrial partner