Antimicrobial Coating of Surgical Meshes by Laser-Induced Nanocarbon Synthesis and Transfer

Conformal coatings on polypropylene (PP) surgical meshes remain challenging because filaments, knots, and junctions create shadowing and PP is thermally sensitive. We introduce laser-induced nanocarbon synthesis and transfer (LINCSAT), a one-step toner-assisted process that deposits porous sp²-rich carbon from a donor precursor onto PP without melting. Electron microscopy and Raman spectroscopy confirm continuous nanocarbon coverage across 3D mesh filaments and knots. 3D profilometry reveals a coating thickness up to ≈40 μm and enables antibacterial mapping versus local thickness. Escherichia coli live/dead assays show a nonmonotonic response, with ≈15 μm coatings minimizing viability. Overall, LINCSAT enables programmable antibacterial coatings on 3D thermoplastics.