Expanding Markets On A Miniature Scale

High-precision laser micromachining is enabling the cost-effective creation of extremely small features in a wide range of ceramic components.

By Dr. Alan Ferguson, Director, Oxford Lasers

Components made from alumina (Al2O3), silicon nitride (Si3N4), aluminum nitride (AlN) and other ceramic materials are used in a wide range of electronic, automotive, aerospace, medical, and other high-tech applications. As these application areas continue to grow, manufacturers must find new and better solutions for machining these materials so that they can produce parts more cost effectively and on an increasingly smaller scale. While lasers have been used to drill, cut, and scribe ceramics for many years, the latest generation of laser systems offers new micromachining possibilities in ceramics.

The Evolution Of Lasers
Traditional mechanical machining/drilling of fired Al2O3 and other ceramic materials is difficult and expensive due to the hardness and brittleness of these materials. Sawing or scribing can be accomplished using diamond blades; however, this method results in large kerf widths, blade wear, and increased production costs, and it is impractical for cutting complex profiles. Mechanical machining methods become even more unattractive as the requirement for smaller and more accurate features increases. Electrical discharge machining (EDM) can be used on certain conductive materials, but it does not have a broad application range.