Direct Laser Interference Patterning (DLIP) is an established method for fabricating micro- and nanoscale surface structures, enhancing properties such as friction or wetting. Traditionally, this technique uses a gantry system to move either the laser tool or the component, which, despite offering high precision and speed, is limited in flexibility, especially for large 3D parts. This study presents an innovative approach that integrates DLIP with an industrial robot, increasing the degrees of freedom and enabling the structuring of large components. The DLIP tool, including a specially developed nanosecond pulsed laser, is directly attached to a robot arm. This configuration reduces weight and accommodates typical robot-induced vibrations. The optics is designed to generate an elongated rectangular beam with a long depth of focus, enhancing system robustness by directly coupling the optics and the laser source, eliminating the need for mirrors. Initial experiments involved structuring stainless steel using a pulse frequency of up to 4 kHz and an output power of approximately 65 W, with structuring speeds ranging from 2 to 120 mm/s.

To ensure high-quality outcomes in an industrial setting, this method incorporates an in-line monitoring system using infrared imaging to observe radiation emissions from local heating during DLIP. This system detects average temperatures and temperature field sizes, enabling real-time adjustments and quality assurance. The fabricated structures topographies were analyzed using confocal microscopy, establishing correlations between process parameters, monitoring data, and resulting patterns. This advanced method not only enhances the flexibility and applicability of DLIP for large components but also integrates robust process monitoring to ensure consistent high-quality production.