Laser processing is a well-known technique in modern manufacturing. Among the various types of lasers, COâ‚‚, fiber, and semiconductor lasers have long dominated industrial applications. However, in recent years, ultra-short pulse laser technology has advanced rapidly, especially in the femtosecond and picosecond regimes. This breakthrough has opened up new possibilities in precision micromachining, which we will explore today.
Micromachining with lasers has been explored for decades, but early attempts were limited by long pulse widths and low energy densities. These factors caused significant thermal effects, leading to material melting and evaporation, which reduced precision. To improve accuracy, it became essential to minimize heat input. When lasers operate at picosecond or femtosecond pulse durations, the interaction time with the material is extremely short. This allows high power density to strip electrons from the surface without transferring heat to surrounding areas—hence the term "cold processing."
This cold ablation method enables precise removal of material without damaging the surrounding area. As a result, ultra-short pulse lasers have found widespread use in industrial settings, offering unmatched precision and control.
How fast are these pulses? A picosecond is 10â»Â¹Â² seconds, and a femtosecond is 10â»Â¹âµ seconds—extremely short timescales. To put this into perspective, light travels about 0.3 mm in one picosecond. That’s faster than most human reactions, making these lasers ideal for delicate operations.
What can such speed achieve? The rapid development of short-pulse laser technology has led to a wide range of industrial applications. Today, these lasers are used in drilling, scribing, cutting, surface structuring, and engraving. For example, in circuit board manufacturing, picosecond lasers are used to drill thousands of tiny holes without damaging the substrate. They are also used to cut transparent materials with minimal kerf width, making them ideal for high-precision tasks.
Another key application is the removal of coatings without harming the underlying material. This is particularly useful in solar panel production and automotive manufacturing, where protective layers need to be removed before further processing. Surface structuring is another area where ultra-short pulses shine, allowing the creation of hydrophobic or hydrophilic surfaces for improved performance.
Engraving is another important use, where three-dimensional features are created on hard materials like polycrystalline diamond. Lasers offer non-contact, high-accuracy machining, making them a preferred tool in precision engineering.
In summary, laser micromachining is revolutionizing many industries with its ability to perform highly accurate, non-thermal processing. As the technology continues to evolve, more everyday products will benefit from the precision and versatility of ultra-short pulse lasers.
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