Laser ablation is the process of using a high-powered, focused laser beam to remove layers of material from a solid surface. In this article, we explore how industrial laser ablation works, the different types of laser ablation, its many advantages, and how Novanta Photonics’ industry-leading solutions can transform your operations. Contents What is industrial laser ablation? How does laser ablation work? Laser ablation parameters Types of laser ablation What is laser ablation used for? Materials Industries Applications Laser ablation: advantages and disadvantages Precision laser ablation solutions by Novanta Photonics What Is Industrial Laser Ablation? Industrial laser ablation is a precision process that uses laser systems to remove individual layers or contaminants from solid material. Ablation is used to uncover new layers of material, and to create intricate engravings or designs, including on micron-sized areas. Laser ablation is a non-contact process, so there’s minimal toolwear and little maintenance required. Thermal damage and warping is also kept to a minimum, further enhancing quality. In addition, no chemicals or other consumables are required, making laser ablation one of the more sustainable material processing techniques. Laser ablation is also incredibly versatile, used by global industries for myriad applications, including removing rust, oxide or paint, and creating detailed, complex designs. How Does Laser Ablation Work? A focused laser beam is directed onto a substrate to remove individual layers to reveal the underlying material, or to create surface structures. Ablation occurs only when the material absorbs sufficient energy to be melted or vaporized, and the material is subsequently converted into a plasma or gas. Laser ablation is widely used in the fabrication of metals, ceramics, glasses, and polymers. Advanced control software can direct the laser beam in a particular pattern to create intricate designs, by gradually removing micro spots of material. Industrial laser ablation systems typically use CO2 lasers, nanosecond or ultrafast lasers, alongside scan heads or polygons to generate faster speeds. A 3-axis scan head can be utilized to trace the outline of 3D surfaces, ensuring consistent results across the entire area. Laser Ablation Parameters Industrial laser ablation is controlled by several parameters, with each influencing the overall quality and finish of the final result. These parameters include: Wavelength: the wavelength of a laser impacts how much energy the target material is able to absorb, influencing the overall efficiency and quality of the process Pulse length: this is the time the laser is ‘on’. The short pulses needed for ablation can range from nanoseconds to femtoseconds Pulse frequency: this refers to the number of pulses per second. Increasing the frequency reduces the energy per pulse and therefore the effectiveness of the ablation process Pulse peak power: laser pulse peak power refers to the highest optical power a pulse can reach during its short duration. Higher peak power results in a more efficient ablation process Spot size: the ‘spot’ is the area where the laser energy is focused; a smaller focus spot can create more intricate features and has a higher energy density, enabling more efficient ablation Focal distance: this is the distance from the focussing lens to where the laser focus spot is smallest. The material surface should always be ‘in focus’; the smallest spot should be directly on the surface to achieve the best ablation results. For 3D-shaped materials or when creating deep structures, a 3-axis scan head can be used to optimize the focal distance Types of laser ablation There are several different types of industrial laser ablation, including continuous wave, nanosecond and ultra-short pulsed. Each has advantages and disadvantages, with the best choice depending on the specific application requirements. 1. Continuous wave laser ablation Continuous wave (CW) laser ablation emits a steady, consistent laser beam to vaporize layers of material. Due to the prolonged interaction with the material, high heat stress is induced, which can result in thermal damage. For industrial laser ablation, the laser interaction time and sufficient intensity are crucial. This method has high ablation rates, making it suitable for industrial applications where large areas need to be processed quickly, such as surface cleaning and engraving. 2. Nanosecond pulsed laser ablation Nanosecond lasers emit pulses of considerable length. The duration of these pulses can cause heating and thermal alteration or damage to the material being processed. Nanosecond lasers are advantageous for applications requiring rapid material removal or high throughput due to their higher ablation rates. While effective for the ablation of metals and various other materials, they may be less suitable for delicate materials due to their thermal effects. 3. Ultra-short pulsed (USP) laser ablation USP laser ablation is a precise material removal technique that uses short, intense laser pulses to ablate materials, leaving minimal thermal damage. Due to the short interaction time, this ablation process is also known as ‘cold ablation’. This method is valuable for applications where high surface quality and minimal heat-affected zones are required, such as surface modification, thin film deposition, and solar cell production. In comparison to the other ablation types, USP lasers may have lower ablation rates, especially in materials with higher thermal conductivity. What is laser ablation used for? Industrial laser ablation is highly versatile, as it can be used to process a wide range of materials, while delivering extreme precision and quality. Novanta Photonics’ laser ablation solutions are used across multiple industries for a variety of applications, from creating intricate designs to texturing complex parts with extreme precision. Materials The following materials are suitable for processing via laser ablation: Metals, including aluminium and steel Semiconductor materials Ceramics Glass Wood Stone Polymers, including polyimide and PTFE Tissue Industries Sectors that utilize industrial laser ablation techniques include: Manufacturing Automotive Aerospace Electronics Energy Medical device manufacturing Packaging and labeling Chemical analysis Applications Laser ablation is used in a wide range of applications, such as: Drilling and shaping complex parts Surface modification and texturing Laser marking Laser engraving Laser micromachining Cleaning surfaces from oxides, paint, or other contaminants Coating removal Chemical analysis Nanomaterial synthesis Laser ablative surgery Laser Ablation: Advantages & Disadvantages There are many advantages of laser ablation compared to traditional ablation methods, with lasers able to operate at faster speeds and deliver enhanced precision. However, as with all technologies, there can also be some perceived challenges around implementing laser ablation solutions. Advantages Disadvantages Automated for enhanced efficiency and productivity Cost of initial investment in laser equipment Extreme precision May produce harmful fumes, depending on the material High speed Slower to remove material from larger or thicker surfaces Highly repeatable Requires post-processing Versatile Risk of material warping due to thermal damage Non-contact process Integration with existing systems can be challenging Little maintenance required Sustainable, as no chemicals involved Minimal waste Cost-efficient Novanta Photonics will work with your organization’s OEMs to ensure our laser components and subsystems integrate seamlessly with your existing systems, with our software giving you full control over the parameters for enhanced efficiency. While initial investment in equipment is required, laser ablation’s sustainability and associated cost savings can help to improve spending efficiencies in the long term. Precision Laser Ablation Solutions by Novanta Photonics Improve your organization’s versatility and efficiency with market-leading laser ablation technology by Novanta Photonics. With over 35 years’ experience developing precision laser solutions, we power tomorrow’s industries with innovative, cutting-edge solutions. Businesses around the world use our components and subsystems for a range of processes, including laser ablation, laser cutting, engraving, marking and coding, and more. Contact us today to speak to our team about how our precision laser solutions can transform your processes. Request an Application or Material Test
