Perfection through light: the power of laser processing

Laser processing uses the laser as a tool to cut, engrave, or weld workpieces precisely, efficiently and without contact. Different types of lasers and processes enable the processing of many materials. In contrast to laser material processing, the focus here lies on the process and precision rather than on the material reaction.

What is laser processing?

Laser processing encompasses all processes in which a laser is used in a targeted manner to process workpieces. Whether cutting, engraving, welding or shaping: the laser works without contact and achieves high precision. Complex geometries can be reliably implemented without mechanical tools wearing out.

Difference between laser processing and laser material processing

Laser processing and laser material processing are often used synonymously, but there are slight differences between the two terms:

Laser processing

Laser processing considers the laser as a tool and focuses on its technical application. It is about how the laser implements various processes, how efficient these processes are, and what advantages they offer for manufacturing, automation and series production. The focus is on process benefits, speed and precision, regardless of the physical properties of the material.

Laser material processing

Laser material processing, on the other hand, focuses on the material itself and its reaction to the laser. The emphasis here is on physical processes such as absorption, melting or evaporation. Research is conducted into how different materials – such as metal, plastic, ceramics or glass – react to the laser beam and which process parameters are necessary to achieve optimum results.

In summary:

• Laser processing = the laser as a tool
• Laser material processing = the laser as an influence on the material.

Which materials can be processed with a laser?

In principle, many materials can be processed using lasers. These include metals such as stainless steel, aluminium and copper, plastics, wood, glass, paper and textiles. Depending on the material and type of laser, cutting, engraving or marking can be carried out with precision. Laser applications in power electronics and the laser processing of ceramics and photovoltaic modules also play a decisive role in industry. The choice of the appropriate laser process depends on the properties of the material and the desired result.

Laser processing methods

All laser processing methods use concentrated laser energy, but they differ in intensity, focus, and effect depending on the application:

Laser cutting

Laser cutting uses a focused laser beam to cut materials precisely and cleanly. Due to the high energy input, the material melts or vaporises along the intended cutting line, without any contact from mechanical tools. This enables fast and flexible cuts with high repeatability, making the process particularly suitable for sheet metal, plastics and many other materials.

Laser engraving and marking

Laser engraving and laser marking are used to specifically alter surfaces without completely penetrating the workpiece. The laser either removes material from the surface (laser ablation) or changes its structure to create durable and precise markings such as logos, serial numbers, or decorative patterns. These processes are particularly durable and resistant to wear.

Laser drilling

Laser drilling produces fine, usually circular openings in materials. Due to the high energy of the laser beam, holes with very small diameters and high accuracy can be created. This technique is used in applications requiring microscopically precise drilling, such as electronics manufacturing or medical technology.

Laser welding and soldering

In laser welding, two workpieces are heated at a precisely focused point until the material melts and fuses together, forming a stable joint.

Laser soldering works in a similar way, but with the addition of a third material, known as solder. This solder melts under the laser beam and bonds the workpieces without completely melting the base materials. This makes the process particularly suitable for sensitive or dissimilar materials.

Laser cladding

Laser cladding is an additive process in which a workpiece is locally melted by a laser beam while being coated with an additional material (usually in powder form). In this way, a new surface is built up layer by layer — for example one that is particularly resistant to wear or corrosion.

Additive manufacturing with lasers

In additive manufacturing, often referred to as 3D printing, the laser builds components layer by layer by precisely melting and solidifying metal or plastic powder. This process enables the production of complex geometries and customized components that would be difficult or impossible to achieve using traditional methods.

Laser surface treatment

Laser energy is used to specifically influence surfaces in order to improve material properties. For example, laser hardening can be used to heat the surface layer of a component, making it more wear-resistant. Such treatments increase the service life of tools and machine parts and improve their performance.

Which lasers are used in laser processing?

Depending on the material and the application, different types of lasers are used in laser processing.

CO₂ Lasers

CO₂ lasers are true all-rounders. Operating in the infrared range, they are particularly well suited for non-metallic materials such as wood, plastics, or glass. Their high power enables precise cutting and engraving with consistently clean edges.

Nd:YAG Lasers

Nd:YAG lasers stand out for their versatility in processing metallic materials. They penetrate deeper into the material and are ideal for applications such as welding, drilling, or hardening, where a high energy density is required.

Ultra-short pulse lasers

Ultra-short pulse lasers operate with extremely short pulses in the femtosecond or picosecond range. This allows materials to be processed particularly gently and precisely without causing thermal damage, which is perfect for sensitive materials such as ceramics, glass or composites.

Opportunities and limitations of laser processing

Laser processing offers impressive high precision, flexibility and reproducibility. Complex geometries and a wide variety of materials can be processed efficiently, often automatically and ready for series production. At the same time, however, it requires investment in high-quality equipment, trained specialist and careful process planning, as the material, geometry and desired effects must be precisely matched to each other.