LASER MICROMACHINING
particularly true for ultrashort pulses. High repetition rates with sufficiently high pulse energies are therefore necessary. One approach to improving both throughput and the precision of laser micromachining is to use tailored pulse bursts and pulse shapes. Using this approach, the temporal profile of the energy deposited can be optimised for a particular material so that incident energy is directed almost entirely to removal, rather than heating. The laser beam profile and
the performance of the beam- delivery optics are also of critical importance for laser micromachining applications. The beam-profile must be delivered in a single spatial mode to realise a tight, round focal spot on the sample. Each optical
element between the laser and the target workpiece can distort the beam incrementally, so both the number and quality of the optical elements need to be optimised for each application. If this isn’t done, optics with insufficient surface quality might be used, which can distort the shape of the beam. Alternatively, optics with an insufficiently clear aperture might be used, which can crop the beam and introduce undesirable diffractive effects. Such distorted or cropped beams would reduce the overall quality and accuracy of the micromachining process.
Industries served by micromachining The use of lasers to micromachine fine features on parts has become an essential part of high-volume manufacturing in industries such as consumer electronics, clean energy, medical device manufacturing and automotive. Generally speaking, these industries are increasingly demanding parts that are smaller and have finer, more densely packed features. Smartphones, for instance,
contain thousands of components featuring huge numbers of holes and precision cuts, and well over a billion of them are sold each year. The need to add more functionality to smartphones has forced
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manufacturers to fabricate printed circuit boards (PCBs) with smaller, more densely packed features. As such, laser micromachining is used for this purpose, and in the fabrication of semiconductor chips and their packaging. The manufacture of high-resolution touchscreen displays also relies on many laser micromachining processes. In the clean energy industry
laser micromachining is used, for example, to rapidly create fine features on photovoltaic panels to increase their efficiency, or in the production of lithium-ion batteries. In the automotive and
Laser micromachining firm Lightmotif can apply pillar textures to mould inserts
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aerospace industries, lasers are used to machine parts made from lightweight materials such
“Ultrafast
lasers are being increasingly deployed to produce nanostructures that imbue surfaces with a range of functional properties”
as carbon fibre-reinforced plastics (CFRPs), which can be difficult, or even impossible, to machine using conventional processes. In the medical industry, laser
micromachining is being used to produce the increasingly
g THE 2023 GUIDE TO LASER SYSTEMS LASER SYSTEMS EUROPE 51
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