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The formation and stability of stationary laser weld keyholes are investigated using a numerical simulation. The effect of multiple reflections in the keyhole is estimated using the ray tracing method, and the free surface profile, flow velocity and temperature distribution are calculated numerically. In the simulation, the keyhole is formed by the displacement of the melt induced by evaporation recoil pressure, while surface tension and hydrostatic pressure oppose cavity formation. A transition mode having the geometry of the conduction mode with keyhole formation occurs between the conduction and keyhole modes. At laser powers of 500 W and greater, the protrusion occurs on the keyhole wall, which results in keyhole collapse and void formation at the bottom. Initiation of the protrusion is caused mainly by collision of upward and downward flows due to the pressure components, and Marangoni flow has minor effects on the flow patterns and keyhole stability.

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Experimental investigations aimed at assessing the effectiveness of femtosecond (FS) laser ablation for creating microscale features on electrospun poly(ε-caprolactone) (PCL)/gelatin nanofiber tissue scaffold capable of controlling cell distribution are described. Statistical comparisons of the fiber diameter and surface porosity on laser-machined and as-spun surface were made and results showed that laser ablation did not change the fiber surface morphology. The minimum feature size that could be created on electrospun nanofiber surfaces by direct-write ablation was measured over a range of laser pulse energies. The minimum feature size that could be created was limited only by the pore size of the scaffold surface. The chemical states of PCL/gelatin nanofiber surfaces were measured before and after FS laser machining by attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectroscopy and X-ray photoelectron spectroscopy (XPS) and showed that laser machining produced no changes in the chemistry of the surface. In vitro, mouse embryonic stem cells (mES cells) were cultured on as-spun surfaces and in laser-machined microwells. Cell densities were found to be statistically indistinguishable after 1 and 2 days of growth. Additionally, confocal microscope imaging confirmed that spreading of mES cells cultured within laser-machined microwells was constrained by the cavity walls, the expected and desired function of these cavities. The geometric constraint caused statistically significant smaller density of cells in microwells after 3 days of growth. It was concluded that FS laser ablation is an effective process for microscale structuring of these electrospun nanofiber tissue scaffold surfaces.