Pinpoint material processing with laser technology

Ultrashort pulse lasers are highly precise tools that process materials with pinpoint accuracy through extremely short pulses, without causing thermal damage. Their versatility, combined with the ability to use different wavelengths and beam shapes, makes them indispensable in industry, research, and medical technology. Despite high acquisition costs and complex process control, continuous advancements and new technologies offer ever-increasing efficiency and precision.

What is a USP laser?

A USP laser is a specialized type of laser that generates extremely short light pulses in the picosecond (10⁻¹² seconds) to femtosecond (10⁻¹⁵ seconds) range. These ultrashort pulses concentrate enormous amounts of energy into tiny time intervals. When the laser beam strikes a material, it vaporizes it within fractions of a second—without heat penetrating into adjacent areas.

Cold processing through ultrashort pulses

The extremely short pulse duration of a USP laser enables what is known as cold processing. In this process, the material does not melt—instead, it transitions directly into a gaseous state. This makes the process exceptionally precise and gentle on materials, representing a key difference compared with conventional laser methods, which often introduce significant thermal load.

Material processing at high peak powers

The extremely high peak intensities of USP laser pulses make it possible to perform material processing tasks that cannot be achieved with longer pulses or continuous-wave lasers. At these peak power levels, nonlinear absorption processes occur, enabling precise structuring even of materials such as glass, ceramics, or plastics.

How does an ultrashort pulse laser work?

The technology behind a USP laser is based on mode locking, in which light waves inside the resonator are synchronized to generate ultrashort pulses with extremely high peak power. Depending on the application, different laser types — such as solid-state or fiber lasers — are used. This combination of high energy and ultrashort pulse duration enables material processing down to the nanometer scale.

Factors influencing the functionality of a USP laser

Several parameters determine how precisely and efficiently a USP laser operates. They influence processing speed, the quality of the results, and the level of material preservation.

Wavelength

The wavelength of a laser influences how strongly a material absorbs the light and how finely structures can be processed. Shorter wavelengths, such as UV, are absorbed particularly effectively and enable precise processing even of materials that are barely reactive to infrared light.

Pulse duration

The duration of a single pulse determines how quickly energy is delivered into the material. The shorter the pulse, the less time heat has to spread. This enables highly precise processing with a minimal heat-affected zone.

Pulse energy

The amount of energy delivered per pulse determines the depth of material removal per processing step. Higher pulse energies accelerate ablation but require precise process control to avoid cracks or unintended material damage.

Repetition rate

The pulse repetition rate indicates how many pulses are generated per second. A higher repetition rate enables faster processing but can lead to heat accumulation if excess heat is not dissipated in time.

Beam quality

Beam quality, often expressed by the so-called M² value, describes how well the laser beam can be focused. A low M² value allows for particularly sharp focusing and thus enables the processing of extremely fine structures.

Focus diameter

The diameter of the focused beam influences the achievable resolution of the processing. Small focus spots enable high-precision machining but require very stable and highly accurate beam guidance.

Types of USP lasers

USP lasers are available mainly as solid-state or fiber lasers, which differ in their design and areas of application.

Solid-state lasers

Solid-state lasers use a sapphire crystal doped with titanium as the active medium to generate laser emission. They achieve extremely high peak powers and are primarily used in applications that require maximum precision and ultrashort pulses—for example, in research or microstructuring.

Fiber lasers

Fiber lasers guide the light inside an optical fiber, making the systems compact, robust, and easy to cool. They are particularly well suited for industrial manufacturing processes where stability, simple integration, and scalability are essential.

Application areas of USP lasers

Ultrashort pulse lasers are used across many industries and research fields for laser processing because they allow extremely precise and material-gentle processing.

Electronics and semiconductors

In the electronics industry, USP lasers are used to structure fine conductor paths on printed circuit boards, create vias, or process semiconductor wafers, applying the principles of laser cutting. Their high precision and minimal thermal effects make them ideal for delicate components and complex microstructures inpower electronics.

Photovoltaics

In photovoltaics, manufacturers use USP lasers to cut, structure, or perforate solar cells with high precision. This exact processing enables efficient cell layouts while minimizing material loss.

Medical technology

USP lasers are also used in medical technology, for example in the production of precision instruments or in microsurgery. Their ability to process materials without contact and without causing thermal damage is especially valuable in this field.

Research and development

USP lasers also play a key role in research. They are used to test material properties, analyze surfaces, or develop new manufacturing processes. The ability to create extremely small structures with nanometer accuracy opens up numerous scientific applications.

Trends and advancements

USP lasers continue to evolve. New laser technologies and concepts improve precision, efficiency, and application diversity, opening additional possibilities for industrial and scientific use.

Multibeam systems

A growing trend is multibeam systems, where several laser beams are used simultaneously. This increases processing speed — especially for large-area applications — without compromising precision.

New wavelengths

UV and DUV lasers open new possibilities in precision processing. They provide higher resolution and improved absorption for specialized materials, enabling even the finest structures to be produced reliably.

Automation and integration

USP lasers are increasingly integrated into automated production lines, implemented through advanced laser systems. This enhances process reliability, increases efficiency, and simplifies integration into industrial manufacturing processes.

Increased performance and compact system design

Modern USP systems have become more efficient and more compact. More efficient amplifiers and smaller system architectures increase flexibility and enable deployment across a wide range of production environments.