Ultrafast laser high-aspect-ratio extreme nanostructuring of glass beyond λ/100
Abstract
The ultimate feature size is key in ultrafast laser material processing. A capacity to signiicantly exceed optical limits and to structure below 100nm is essential to advance ultrafast processing into the field of metamaterials. Such achievement requires to combine the control of optical near-fields and of material reactions, while preserving the exibility of long working distances, compatible with a mature laser process. Using sub-ps and ps non-diffractive Bessel beams, we demonstrate unprecedented feature sizes below a hundredth of the incident 1$\mu$m wavelength over an extended focus depth of tens of $\mu$m. Record features sizes, down to 7nm, result from self-generated near-field light components initiated by cavities induced by far-field radiation in a back-surface illumination geometry. This sustains the generation of more confined near-field evanescent components along the laser scan with nm pitch, perpendicular to the incident field direction, driving by local thermal ablation a super-resolved laser structuring process. The near-field pattern is replicated with high robustness, advancing towards a 10nm nanoscribing tool with a $\mu$m-sized laser pen. The process is controllable by the field orientation. The non-diffractive irradiation develops evanescent fields over the focusing length, resulting in a high aspect ratio trenching with nm section and $\mu$m depth. Higher energy doses trigger the self-organization of quasi-periodic patterns seeded by spatially modulated scattering, similarly to optical modelocking. A predictive multipulse simulation method validates the far-field-induced near-field electromagnetic scenario of void nanochannel growth and replication, indicating the processing range and resolution on the surface and in the depth.