Laser Surface Structuring Applications & Benefits

Laser structuring improves coating adhesion significantly. In the laser structuring process, the laser will remove contaminants and oxides and form a microstructure. This microstructure is easier to stick to, due to the increased surface area, and also helps prevent contaminants and oxides from collecting on the surface in the future.

Using laser surface structuring for coating adhesion is common in the automotive, aerospace, and EV industries.

Structured surfaces allow more control and more even distribution of liquids across their surface than bare surfaces. Typically adhesives, or other liquids, are hard to control due to the bonding within the liquid itself. This can cause pooling or lead to excess material usage.

However, using a laser to structure the surface allows for control over how the liquid rests on that surface. For instance, different shapes can be lasered on a surface and the liquid applied will remain exclusively in that area. In addition to controlling the area that the liquid is applied; it will also result in a more even distribution. This allows manufacturers to use less adhesive for a stronger bond between mating pieces.

Laser surface structuring is used to prepare grinding tools for better effectiveness when cutting grain. The precision of a laser and the micro-textures produce fewer cutting edges while preserving the strength. With fewer edges, the tool uses less force and doesn’t deform materials during the grinding process.

Laser structuring increases friction control on parts and components by adding rough patterns and shallow engravings. Friction control is helpful for automotive and ship brake discs.

The precision of the laser and its structures means that there’s more control over how the friction interacts with the discs and engine. With more control, there’s more effective wear and tear management. Lasers create more precise patterns than other methods like thermal spray, chemical etching, and sandblasting.

Laser surface structuring takes seconds to add a structure onto a surface and does not require pretreatment processes. The speed of part marking not only indicates faster structuring but also frees time for other processing and progression down the supply chain.

Alternative methods like chemical etching, sandblasting, and Pasa-Jell require pre- and post-treatments on the part that add more time. Even more, these treatments can sometimes take hours for the final result.

Laser surface structuring does not use chemicals or other toxic consumables.

Alternative structuring methods use acids and sealants for the structuring. The disposal of these is harmful to the environment and technicians.

Laser structuring is known for focused precision. Machines differ, but lasers can mark on the micron level. For reference, 100 micron is about the width of a human hair.

The laser’s precision contributes to the effectiveness of laser structuring applications. The more precision, the more control manufacturers have over the results.

A fiber laser gets its name from the fiber oscillator—the optical fiber. The laser beam travels through the optical fiber and comes out as a 1090 nm infrared wavelength.

Fiber lasers have high output power, which means that their laser is powerful enough for deep engraving, fast marking, and metal projects. These lasers are also known for long service life, speed, and reliability.

UV lasers use a process called photolytic degradation, also known as “cold marking,” with a 355 nm UV wavelength.

The 355 nm wavelength has little to no heat transfer onto the surface while still being strong enough to mark on surfaces with high heat resistance. Because of this uniqueness, a UV laser is known for its ability to mark on two ends of the spectrum—heat-resistant and heat-sensitive materials.

Fiber lasers are known for metalworking and fast speed. If those characteristics resonate with you, then a fiber laser is the answer for you.

Other considerations for choosing a fiber laser are for deep laser marking or large production batches. If you are looking for a versatile laser that can also tackle other materials like plastics and glass, a fiber laser is not a good choice.

A UV laser is a good part marking equipment if you manufacture parts made of resin, glass, or plastic. Although UV lasers can also mark your metal components, a UV laser will not be successful for deep impressions. Therefore, if you are looking to mark metal or metal coatings with no damage then UV lasers would be the optimal choice.

Hybrid lasers are a special type of laser that doesn’t fall into one “category.” Instead, these lasers combine a YVO₄ laser and a fiber laser to make a hybrid. Since hybrids are not completely fiber lasers, they have more versatility.

Hybrid lasers have the strengths of a fiber laser—deep engraving, specialty in metalworking, and speed—while still having delicacy. These lasers can mark plastic and resin in addition to metal.

If you’re stuck between the UV laser and fiber laser for part marking, then a hybrid laser may be a good compromise for you.