Laser processing of freeform surfaces: a new approach based on an efficient workpiece partitioning strategy

Afif Batal*, Aleksandra Michalek, Pavel Penchev, Axel Kupisiewicz, Stefan Dimov

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

24 Citations (Scopus)
286 Downloads (Pure)


A novel method for laser processing freeform surfaces is proposed and demonstrated in this article. The method employs empirical data on the 3D limitations of a given laser process, namely the negative effects of focal offset and angle of incidence on the process performance, to partition a freeform surface into triangular laser processing fields. In this way, processing efficiency can be maximized by minimizing part repositioning while fully utilizing the capabilities of high dynamics galvo scanners. In this proof of concept, the surface of 3D printed Ti–6Al–4V spherical shells was improved by more than 90% and subsequently textured, using the proposed method. Conclusions were made about the advantages of this new approach for processing freeform surfaces consistently and efficiently.

Original languageEnglish
Article number103593
Number of pages12
JournalInternational Journal of Machine Tools and Manufacture
Early online date23 Jun 2020
Publication statusPublished - Sept 2020

Bibliographical note

Funding Information:
The research reported in this paper was supported by a H2020 Factory of the Future projects, “High-Impact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities” (HIMALAIA) and the UK-India Education and Research Initiative ( UKIERI ) DST programme “Surface functionalisation for food, packaging, and healthcare applications”. The authors would like to acknowledge also the collaboration with LASEA SA, Belgium within the framework of the ESIF project “Smart Factory Hub” (SmartFub).

Publisher Copyright:
© 2020 Elsevier Ltd


  • 3D laser processing
  • Additive manufacturing
  • Freeform surface
  • Laser polishing
  • Laser texturing
  • Surface partitioning

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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