Bioinspired Laser Additive/Subtractive Manufacturing of Ti6Al4V Alloy for Photo–Thermo–Electric Generation

Zichao Jiang; Yuan Kong; Xue Jiang; Ruijie Liu; Liyaowei Shen; Shenmin Zhu; Anping Dong; Zhuguo Li; Dongshi Zhang

doi:10.1016/j.eng.2026.04.020

Engineering ›› :202604020 DOI: 10.1016/j.eng.2026.04.020

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Bioinspired Laser Additive/Subtractive Manufacturing of Ti6Al4V Alloy for Photo–Thermo–Electric Generation

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Abstract

As a cutting-edge paradigm in renewable energy systems, photothermoelectric generation (PTEG) epitomizes next-generation sustainability through the integration of selective absorbers. Inspired by the ultra-black wing nanostructures ofTrogonoptera brookiana butterflies, black absorbers were fabricated on laser additive manufactured (LAM) Ti6Al4V alloy substrates (piece-by-piece segmented by wire-electrode cutting) using femtosecond laser subtractive manufacturing (fs-LSM) for PTEG applications. The resultant hierarchical architectures, comprising macropores and laser-induced periodic surface structures (LIPSSs), exhibited remarkable morphological and spectral resemblance to natural black butterfly wings. The PTEG output power and operational stability of the as-prepared functional Ti6Al4V interfaces were regulated by structural layout and post-thermal oxidation annealing. Under one-sun irradiation, the fs-LSM-structured absorber achieved a maximal peak power density of 51.38 μW⋅cm⁻², maintained stable output power over 80 min of continuous operation, and sustained performance over 10 PTEG on–off cycles. The developed absorber ranks among the highest-performance fs-laser-processed absorbers reported to date, rivaling and even surpassing many phase-change materials. After 6 months of storage, the PTEG performance remained highly robust, with only slight fluctuations during 12 h of operation. A comparative analysis of PTEG performance for LAM/fs-LSM absorbers subjected to two-round 1 h and 1 h + 3 h thermal-oxidation annealing revealed that the localized surface plasmon resonance (LSPR) effect induced by oxygen-vacancy engineering effectively mitigated the radiative cooling effect (heat loss) of high-surface-area macropores, overcoming the spectral limitations encountered by ultrabroadband absorbers in PTEG applications. The concurrent manifestation of photothermal harvesting capacity and passive radiative cooling effects makes these materials promising candidates for 24 h persistent PTEG, with strong potential for deployment in remote and harsh environments. These findings may also drive innovations in multifunctional fabrication architectures through integrated “freeform additive manufacturing and micro-/nano-hierarchical functional processing.”

Keywords

Femtosecond laser subtractive manufacturing / Additive manufacturing / Biomimetic fabrication / Photo-thermo-electric generation / Oxygen-vacancy engineering

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Zichao Jiang, Yuan Kong, Xue Jiang, Ruijie Liu, Liyaowei Shen, Shenmin Zhu, Anping Dong, Zhuguo Li, Dongshi Zhang. Bioinspired Laser Additive/Subtractive Manufacturing of Ti6Al4V Alloy for Photo–Thermo–Electric Generation. Engineering 202604020 DOI:10.1016/j.eng.2026.04.020

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