How laser processing is redefining precision manufacturing

Over the past 25 years, laser processing has evolved into a cornerstone of advanced manufacturing. Much like the microchip revolution, laser technologies have become more compact, energy-efficient, and reliable, transforming how we approach high-precision engineering. From smartphones to electric vehicles, laser-based manufacturing is now integral to producing the high-performance components that power our modern world. 

What is laser processing?

Laser processing refers to the use of concentrated light energy to alter materials physically or chemically. This versatile technique spans macro applications like laser cutting and welding, to micro-level processes such as laser micromachining, texturing, and cleaning. It’s a vital tool in digital manufacturing with lasers enabling both speed and precision. 

The science behind laser processing

The term “laser” stands for Light Amplification by Stimulated Emission of Radiation. A process where energy is used to excite atoms in a laser medium, producing a concentrated beam of light. This beam is then amplified and directed with extreme precision, making it ideal as a manufacturing tool.

Unlike natural light, laser light is monochromatic (a single wavelength), coherent (waves are in phase), and highly directional, resulting in a beam with high energy density. These properties are essential for laser material processing, enabling accurate and controlled interaction with a wide range of materials.

Industrial lasers typically operate in the ultraviolet, visible, or infrared spectrum (100nm to 1000nm), and their power, measured in watts, can range from just a few watts to over 100 kilowatts. This power can be delivered as a continuous wave or in pulsed formats (from milliseconds to femtoseconds), depending on the application, such as laser drilling, laser micromachining, or laser welding.

The most widely used laser-type in advanced manufacturing today is the fibre laser, which transmits light through internal reflection within a fibre optic cable. These lasers offer excellent beam quality and flexibility, and the beam itself can be shaped to enhance energy distribution and processing performance. 

Key applications of laser processing in precision manufacturing

Laser processing is indispensable in precision manufacturing, especially when minimal thermal impact and high accuracy are required. Here are some standout applications:

• Micro-electronics: Laser drilling and wafer dicing for high-performance components.
• Laser marking: For traceability and aesthetic enhancements like holograms on consumer electronics.
• Net zero technologies: Including solar panel production and micro-hole drilling in electrolysers.
• High-speed welding and cutting: Used in automotive, aerospace, and nuclear sectors. 

Laser cutting and drilling

Laser cutting is one of the most widely adopted techniques in laser-based manufacturing. Known for its speed, precision, and flexibility, it’s a go-to solution for cutting thin materials across industries. Because it’s a non-contact process with no fixed tooling, laser cutting is ideal for producing a wide variety of designs with minimal setup—making it especially popular in machining centres and custom fabrication environments across the UK.

Laser drilling commonly uses pulsed infrared lasers, often with millisecond pulse durations, to melt and eject material with the help of assist gases like oxygen or nitrogen. This method enables rapid, precise drilling of shaped holes, making it ideal for applications such as cooling holes in aerospace engines, where it often replaces slower techniques like electro-discharge machining.

Recent innovations include water-guided lasers, which use a green wavelength beam delivered through a high-pressure water jet to reduce thermal impact and improve cut quality. High-energy pulsed lasers are also being used to drill hundreds of micro-holes per second in components like industrial filters, pushing the boundaries of precision manufacturing. 

Laser welding

Laser welding is rapidly transforming sectors like automotive, aerospace, and defence by enabling high-speed, high-precision joints. Using primarily infrared wavelengths, laser welding can be performed in continuous or pulsed modes, making it suitable for both macro and micro applications. In electric vehicle manufacturing, for example, it’s one of the few technologies capable of welding battery packs and casings with the required speed and accuracy—sometimes completing multiple welds in under a second.

While materials like aluminium can be challenging due to reflectivity, innovations in beam delivery, green/blue wavelength lasers, and beam shaping have expanded the range of weldable materials. Micro-welding using pulsed lasers is also gaining traction in the healthcare sector, offering low-distortion, high-quality joins for delicate components like wire stents. 

Surface modification

Surface engineering with lasers encompasses a range of techniques including laser cleaning, micro-machining, and texturing. Using ultra-short pulses (pico- and femtosecond durations) manufacturers can ablate surfaces with minimal thermal impact, achieving micron- and even nano-scale (less than a human hair’s width) precision.

This level of control enables functional surface enhancements, such as creating hydrophobic textures or improving adhesion for coatings. These techniques are widely used in electronics and semiconductor manufacturing, where materials like glass can be laser-machined for packaging components.

Laser cleaning is another key application, replacing hazardous chemical processes in industries like aerospace and offering a safe, effective way to remove rust, paint, or contaminants from surfaces. 

Benefits of laser processing in precision manufacturing

Laser-based manufacturing offers several compelling advantages:

• Flexibility: Non-contact and tool-free, adaptable to various platforms.
• Speed: Faster than many traditional methods, with reduced heat distortion.
• Control: Nano-scale precision through pulse-by-pulse modulation.
• Versatility: Effective on metals, polymers, and glass.
• Digitisation: Seamlessly integrates with automation and data-driven systems.
• Sustainability: Generally uses less chemicals than other processes and is very energy-efficient.
• Adaptive process: Laser processing is often the only way to meet the scale and complexity needed for emerging products.

Challenges of laser processing

Despite its many advantages, laser processing comes with specific challenges that can limit its broader use in advanced manufacturing.

Different applications—such as laser welding, micromachining, or drilling—require specialised laser types and wavelengths. This means manufacturers need both the right technical knowledge and the right equipment for each task.  

Another limitation is the need for direct line-of-sight between the laser and the work surface. Complex components often require 5-axis manipulation or custom delivery systems, especially when processing internal features like those inside pipes.

Safety is also a key consideration. Most industrial lasers require enclosed environments to protect operators, which can (but not always) limit flexibility for large-scale or on-site applications. While handheld laser tools are emerging, they are not yet widespread.

Although the UK has strong academic expertise in laser technology, more industrial training is needed to support safe and effective adoption. 

How laser processing supports industry 4.0

Laser processing is a core enabler of Industry 4.0 thanks to its inherently digital nature. Controlled entirely by software, laser systems integrate seamlessly with automation, robotics, and smart manufacturing platforms. This makes them ideal for data-driven production environments where precision, repeatability, and adaptability are essential.

Recent advancements in in-process monitoring and sensor technologies have enhanced the ability to collect real-time data during laser operations. This data is crucial for optimising performance, improving quality control, and building predictive models for future manufacturing processes. However, one of the main challenges remains the speed at which this data must be processed and fed back into the system to influence outcomes in real time.

Innovative solutions like Trumpf’s OCT (optical coherence tomography) and IPG’s LDD product (using inline coherent imaging) have shown promising results in laser welding applications, while techniques such as laser spectroscopy are being used to monitor and refine laser cleaning processes. These developments are paving the way for the integration of artificial intelligence (AI) in laser-based manufacturing, enabling smarter, more autonomous production systems.

As manufacturers continue to embrace digital manufacturing with lasers, the synergy between laser technology and Industry 4.0 will only grow—driving efficiency, traceability, and innovation across sectors. 

The future of laser processing

The UK’s laser processing market is projected to reach £1.5 billion by 2032, driven by its critical role in clean energy, semiconductor, defence, and healthcare sectors. With ongoing innovations in beam shaping, sensing, and additive manufacturing with lasers, the future is bright—almost as bright as the laser beams themselves.