Scalable, large-area patterning of chalcogenide glass (ChG) thin films remains a key challenge for infrared photonic applications. We demonstrate a lithography-free, sphere-assisted laser processing approach that enables parallel and spatially structured surface patterning. Millimeter-scale soda-lime glass spheres were assembled into close-packed hexagonal monolayers on spin-coated As₂S₃ chalcogenide glass films using a pattern-confined packing strategy, followed by sphere-assisted laser processing with a reshaped annular Nd:YAG beam (λ = 1.064 µm). The beam shaping enables controlled energy delivery to the sphere–film interface, facilitating localized thermal modification. Thermal conduction simulations were developed in ANSYS Thermal to predict the temperature distribution and optical skin depth within the ChG thin film.

Hexagonally ordered surface modification patterns were observed after sphere-assisted laser processing, exhibiting circular footprints with a central region surrounded by an annular ring. These features were consistently observed under the present processing conditions. A sun-like feature was observed within the central region, appearing to be associated with optical effects within the spheres.

The predicted thermal fields identified annular sintering regions where the temperature exceeded the glass transition temperature, serving as a validated predictor of the experimentally observed pattern formation.

This approach provides a scalable pathway for large-area surface structuring of chalcogenide glass films for infrared photonic applications.