Laser Drilling

Laser drilling is a highly precise, non-contact process used to create holes in various materials, including metal, ceramic, glass, and delicate polymers. This technique uses a focused laser beam to remove material via photoablation, typically removing microns or tens of microns per pulse.

As an emerging technology, lasers offer more speed and precision than traditional drilling methods. Plus, they can be more cost-effective as they reduce tool wear, minimize waste, and require less setup and maintenance.

As a result, laser drilling is an increasingly preferred alternative to traditional drilling methods.

Any kind of laser can be used to drill holes, and this process works on almost any material or surface. Choosing the right kind of laser depends on the type of material involved. For instance, fiber lasers can be used to perforate pieces of metal, since this material can tolerate higher heat loads.

Each laser type behaves differently. While CO2 lasers usually melt the material to form the opening, fiber lasers use rapid percussion pulses to break through the substrate. Ultraviolet (UV) lasers function in a similar way, but their process is generally slower for the same-sized hole.

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Precision and Accuracy

With any type of laser, the diameter of the holes depends on the spot size. A smaller spot size concentrates energy into a narrower area, which means a higher energy density.

Because spot size affects how tightly the beam is focused, it also determines the precision and quality of the hole. As such, a smaller spot size generally yields more accurate drilling while minimizing peripheral damage.

Because lasers offer a wide range of spot sizes (from large to very small), they allow for the drilling of precise holes of all sizes.

Versatility Across Materials

For most materials, there is a suitable type of laser for hole drilling, whether it is CO2, UV, fiber, or ultrafast lasers.

By adjusting laser parameters such as power, pulse duration and spot size, the process can be optimized for different material properties without tool changes.

This makes laser hole drilling a particularly versatile process.

Reduced Mechanical Stress, Tool Wear, and Cleaning

Because laser drilling involves no physical contact with the material, unlike conventional tools, it eliminates mechanical stress and tool wear. With good fume extraction, lens cleaning is typically needed only every 3 to 6 months.

High Throughput and Automation

Depending on the power of the laser and the material, it’s possible to drill several thousand holes per minute, which is significantly faster than conventional techniques.

Adding robots, XYZ stages, or rotary modules enables automation and can significantly increase throughput.

Minimal Heat-Affected Zone (HAZ)

When it comes to the heat-affected zone (HAZ) (i.e., the region surrounding the hole that is subjected to temperatures high enough to potentially alter the material), hole drilling with the right laser keeps this area minimally affected.

CO₂ lasers produce the largest HAZ, followed by fiber lasers. UV lasers are commonly used since they produce less heat. If really high precision and very little HAZ is required, ultrafast lasers will likely be the best option.

Hole Depth and Diameter Control

The depth and diameter of laser-drilled holes can be precisely controlled by optimizing parameters such as the material, laser type, optical configuration, and processing time. Higher-power lasers can drill faster, but they also tend to introduce more heat into the material.

Laser Drilling Vs. Alternatives

Mechanical Drilling, Drill Press, Drill Bits

Mechanical drilling is useful for low-volume applications, such as when only a handful of holes are required. But this method makes it difficult to drill very small holes (a few hundred microns).

Plus, due to contact between the tool and the material, drill bits can bend or break, increasing system wear and maintenance costs.

Chemical Drilling

Chemical drilling, which involves applying acid and letting it burn through the material, lacks accuracy. It also conflicts with most companies’ desire to minimize or eliminate the use of toxic chemicals.

Plasma drilling / Electrical Discharge Machining (EDM)

Plasma drilling or EDM is a process that removes material from a workpiece through the use of electrical sparks. It can be useful for drilling holes in very hard materials or to create complex shapes.

But it does have limitations: it can only be used on conductive materials, has a slower material removal rate, can cause thermal damage and HAZ, requires costly equipment, and isn’t particularly environmentally friendly or safe.

Applications

Aerospace and Automotive Industries

In the aerospace industry, fiber lasers are generally used to drill holes in fiber composite components and any other part that requires precision and consistency. This includes cooling and vent holes in turbine blades, vanes, and combustion chamber pieces. However, UV nsec and Ultrafast lasers are also utilized in these applications.

In automotive manufacturing, laser drilling can create holes in fuel injector nozzles, which improves fuel efficiency and reduces emissions.

Medical Device Manufacturing

Laser drilling is involved in the production of catheters, tubing, valves, and other liquid-delivery devices. This industry mainly uses UV lasers and ultrafast lasers.

Electronics and Semiconductor Industries

In these industries, fiber, UV, or ultrafast lasers are used to drill holes on almost all components. This includes printed circuit boards, semiconductor components, integrated circuit chips, and inkjet printer nozzles. Because parts are often heat-sensitive, UV or Ultrafast lasers are commonly used.

Energy Sector

Laser drilling (typically UV or ultrafast lasers) is used to create holes in solar cells and in fuel cells for fluid or gas flow passages. Fiber lasers can also work for materials that can tolerate higher thermal loads.

Food and Beverage Industry

This method is also useful for creating ventilation holes in food packaging, allowing products to breathe during transport, as well as micro-holes in bottles or cans that let air flow without allowing liquid to leak. These applications typically rely on UV or ultrafast lasers due to their precision and minimal heat load.

Pharmaceutical Industry

CO2 laser drilling has become the technology of choice to produce precise holes in time-release medications.