Electronic Thesis and Dissertation Repository

Thesis Format



Master of Engineering Science


Mechanical and Materials Engineering


Tutunea-Fatan, O. Remus

2nd Supervisor

Bordatchev, Evgueni V.


National Research Council of Canada

Joint Supervisor


Functional microstructures that consist of V-grooves are one of the geometrical structures that are widely used for a wide range of specific surface engineering applications. The selection of the most appropriate V-groove shape, array, and fabrication technology represents a key step towards the achievement of an optimized functional performance. This thesis addresses the lack of integrated CAD/CAM approaches that are able to parametrically define V-groove structures to be further exploited functionally. To address this need, four integrated frameworks were developed to capture the fundamentals of design and fabrication for V-groove based microstructures. The four semi-automated frameworks presented in this work facilitate the generation of V-groove geometries of an increasing complexity. The usability of each framework was demonstrated by fabricating physical structured surfaces that encompass the intended V-groove geometry.

Summary for Lay Audience

Surface functionality is the ability of a surface to perform a certain skill. The focus of this research is on the micro-/nano-scale, specifically microstructures that can be added to a surface to induce a functionality. Some examples of surface functionality are hydro- and aero-dynamics, sunlight trapping, light guiding, and microfluidics. Although there are many different types of microstructures, V-grooves are one of the most versatile for the implementation of surface functionality. However, high surface quality, precise/repetitive, and burr-less form geometry is of the utmost importance when manufacturing micro-V-grooves. Achieving these qualities provides accurate and optimized functional surfaces. One of the best fabrication techniques for V-groove microstructures is single point diamond cutting (SPDC). The fundamentals of designing, modelling and then fabricating V-groove microstructures has not been developed. Many applications have used V-groove microstructures but none has described a formula or a methodology to create the applied V-grooves. To address this issue, four frameworks were developed to cover a range of V-groove microstructures. The first of the frameworks lays out the fundamentals of modelling and fabricating V-grooves, then it develops the fundamentals into a systematic methodology, which is then turned into an outlined framework. The first framework is meant to cover the biggest range of V-groove applications, straight V-grooves on a flat surface. The second framework then adds in a new aspect to the methodology, an additional rotational axis. With SPDC, the tools cutting face must stay perpendicular to the cutting surface, similar to how a truck ploughs snow. The second framework uses an invoke-able function that allows the tool to maintain its position on the rotating surface, to help ease the cutting of the V-grooves. The third framework is then a new framework that extends the previous framework to include curved grooves. These curved grooves require constant rotation to be fabricated. The final framework includes curved surfaces, to further increase the field’s of research that the frameworks could be used for. Each of these frameworks are implemented to fabricate microstructures to demonstrate the usability of the frameworks.

Available for download on Thursday, January 01, 2026