Ultra-short 230 fs laser pulses of 515 nm wavelength were tightly focused into 700 nm focal spots and utilised in opening ~ 0.4 − 1 μm holes in alumina Al2O3 etch masks with 20-50 nm thickness. Such dielectric masks simplify fabrication of photonic crystal (PhC) light trapping patterns for the above-Lambertian performance of high efficiency solar cells. Conditions of laser ablation of transparent etch masks and effects sub-surface Si modifications were revealed by plasma etch- ing, numerical modeling, and minority carrier lifetime measurements. Mask-less patterning of Si is proposed using fs-laser direct writing for dry plasma etch of Si.

Ultra-short 230 fs laser pulses of 515 nm wavelength were tightly focused into 700 nm focal spots and utilised in opening ~ 400 nm nano-holes in a Cr etch mask that was tens-of-nm thick. Nano-holes ablated at slightly above the threshold of ablation irradiance became nano-disks and nano-rings at slightly lower pulse energies. Subtle sub-1 nJ pulse energy control was harnessed to pattern large surface areas with controlled nano-alloying of Si and Cr. This technique is extendable to vacuum-free large area patterning of nanolayers by alloying them at distinct locations with sub-diffraction resolution. Such metal masks with nano-hole opening can be used for formation of random patterns of nano-needles with sub-100 nm separation when applied to dry etching of Si.

Controlled deposition of CoCrFeNiMo0.2 high entropy alloy (HEA) micro-particles was achieved using laser induced forward transfer (LIFT). Ultra-short laser pulses, 230 fs of 515 nm wavelength, were tightly focused into ∼ 2.4 μm focal spots on the ∼50 nm thick plasma-sputtered films of CoCrFeNiMo0.2. The HTA films were transferred onto glass substrates by magnetron sputtering in vacuum (10−8 atm) from the thermal spray coated substrates. The absorption coefficient of CoCrFeNiMo0.2 α ≈ 6 × 105 cm−1 was determined at 600 nm wavelength. The real and imaginary parts of refractive index (n + iκ) of HEA were determined from reflectance and transmittance using nano-films.

THz band-pass filters were fabricated by laser ablation of micro-foils of stainless steel and Kapton. Their spectral performance was tested in transmission and re- flection at the THz beamline at the Australian Synchrotron (AuSy). A 25 μm Kapton film performed as a Fabry-Pérot etalon with a free spectral range of FSR = 119 cm−1, high finesse Fc ≈ 17, and was tuneable over ~10 μm (at ~5 THz band) with β = 30° tilt. The structure of the THz beam focal region as extracted by the first mirror (slit) shows a complex polarisation-wavelength- position dependence across the beam. This is important for polarisation sensitive measurements (in transmission and reflection) and requires normalisation at each orientation of linear polarisation.

Microlens arrays (MLAs) which are increasingly popular micro-optical elements in compact integrated optical systems were fabricated by femtosecond direct laser write (fs-DLW) technique in the low-shrinkage SZ2080TM photoresist. High fidelity definition of 3D surfaces on IR transparent CaF2 substrates allowed to achieve ∼ 50% transmittance at chemical fingerprinting spectral region 2-5 μm wavelengths since MLAs were only ∼ 10 μm high corresponding to the numerical aperture of 0.3 (the lens height is comparable with the IR wavelength). To combine diffractive and refractive capabilities in miniaturised optical setup, a graphene oxide (GO) grating acting as a linear polariser was also fabricated by fs-DLW by ablation of a 1 μm-thick GO thin film. Such an ultra-thin GO polariser can be integrated with the fabricated MLA to add dispersion control at the focal plane. Pairs of MLAs and GO polarisers were characterised throughout visible-IR spectral window and numerical modeling was used to simulate their performance. Good match between experimental results of MLA focusing and simulations was achieved.

Emerging applications of optical technologies are driving the development of miniaturised light sources, which in turn require the fabrication of matching micro-optical elements with sub-1 mm cross sections and high optical quality. This is particularly challenging for spatially-constrained biomedical applications where reduced dimensionality is required, such as endoscopy, optogenetics, or optical implants. Planarisation of a lens by the Fresnel lens approach was adapted for a conical lens (axicon) and was made by direct femtosecond 780 nm/100 fs laser writing in SZ2080™polymer with photo-initiator. Optical characterisation of the positive and negative fraxicons is presented. Numerical modeling of fraxicon optical performance under illumination by incoherent and spatially extended light sources is compared with the ideal case of plane wave illumination. Considering the potential for rapid replication in soft polymers and resists, this approach holds great promise for the most demanding technological applications.

In this perspective, we give an overview of several less explored structural and optical characterisation techniques useful for biomaterials. New insights into the structure of natural fibres such as spider silk can be gained with minimal sample preparation. Electromagnetic radiation (EMR) over a broad range of wavelengths (from X-ray to THz) provides information of the structure of the material at cor- respondingly different length scales (nm-to-mm). When the sample features, such as the alignment of certain fibres, cannot be characterised optically, polarisation analysis of the optical images can provide further information on feature alignment. The 3D complexity of biological samples necessitates that there be feature measure- ments and characterisation over a large range of length scales. We discuss the issue of characterising complex shapes by analysis of the link between the color and struc- ture of spider scales and silk. For example, it is shown that the green-blue color of a spider scale is dominated by the chitin slab’s Fabry-P ́erot type reflectivity rather than the surface nanostructure. The use of a chromaticity plot simplifies complex spectra and enables quantification of the apparent colors. All the experimental data presented herein are used to support the discussion on the structure-color link in the characterisation of materials.