Spider silk is a tough, elastic and lightweight biomaterial, although there is a lack of tools available for non-invasive processing of silk structures. Here we show that nonlinear multiphoton interactions of silk with few-cycle femtosecond pulses allow the processing and heterostructuring of the material in ambient air. Two qualitatively different responses, bulging by multiphoton absorption and plasma-assisted ablation, are observed for low- and high-peak intensities, respectively. Plasma ablation allows us to make localized nanocuts, microrods, nanotips and periodic patterns with minimal damage while preserving molecular structure. The bulging regime facilitates confined bending and microwelding of silk with materials such as metal, glass and Kevlar with strengths comparable to pristine silk. Moreover, analysis of Raman bands of microwelded joints reveals that the polypeptide backbone remains intact while perturbing its weak hydrogen bonds. Using this approach, we fabricate silk-based functional topological microstructures, such as Mobiüs strips, chiral helices and silk-based sensors.

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We have investigated the effect of the dynamics of crater size on the poly(dimethylsiloxane) (PDMS) surface morphology in fs-laser micro-processing. PDMS surface was processed with varying both inter-pulse interval and inter-spot distance between successive laser pulses. With keeping the interval of 5 ms crater shape is round even if the spot is overlapped in space. But decreasing the interval to 0.02 ms the shape of the crater is no longer round. Decreasing the inter-distance between the craters results in roughened surface morphology even at time intervals of 5 ms. Temporal dependence of single-shot fs-laser induced crater size was measured as a function of time delay. Within 0.1 ms after pulse irradiation with a fluence of 4.8 J/cm2 on PDMS surface the crater size has reached to its maximum values and then decreased with a time constant of about 0.3 ms. The surface morphology after fs-laser pulse irradiation is strongly dependent on not only inter-spot distance between successive laser pulse but also their inter-pulse intervals. By proposing a theoretical model on their dynamic features, we will try to explain the current observation in quantitatively.