Geometry assessment of ultra-short pulsed laser drilled micro-holes

Ultra-short pulsed laser ablation enables a defined generation of micro-holes. A parameter study on the ablation characteristics of copper clearly reveals a benefit for green wavelength with lower threshold fluence, simultaneously increasing the Rayleigh length. The use of a circular drilling method allows a defined manufacturing of micro boreholes and micro through-holes with 35 μm diameter of up to 165 μm and 300 μm length. Introducing high-resolution micro-computed X-ray tomography studying the micro-hole evolution and adjacent geometrical transformations reveals micrometer resolution and high usability. The conical geometry evolving up to an aspect ratio of 5:1 fits well to established models known for percussion drilling. However, increasing the number of pulses leads to non-conical geometry evolution, and this resulting geometry is studied for the first time. Henceforth, the exact geometrical evolution from conical to cylindrical shape upon laser drilling can be resolved revealing the impact of multiple reflections at the generated steep flanks.