Aerospace & Defense Laser Micromachining
Ultra-Precision Laser Cutting & Drilling for Flight, Propulsion, and Mission-Critical Components
Precision Laser Cutting for Mission-Critical Components
Laserod’s precision laser cutting is trusted for the most demanding aerospace applications, including flight, propulsion, and structural systems. Our AS9100 and ISO 9001 certified quality system provides the foundation for the rigor, traceability, and process control required in mission-critical manufacturing. Our process ensures every part meets the tight tolerances and reliability standards critical to mission success.
Aerospace Laser Cutting & Marking Services
Ultra-Precision Laser Cutting
Micron-level cutting of aerospace-grade metals, composites, and ceramics for airframes, propulsion systems, and defense hardware.
Complex Geometry Fabrication
Non-contact laser machining of lattice structures, vent slots, and RF/microwave component patterns for advanced aerospace assemblies.
High-Aspect-Ratio Micro Cuttin
Kerf widths down to 10ÎĽm for turbine blade components, hypersonic vehicle structures, and lightweight UAV frameworks.
Custom Perforation & Slotting
Precision slotting and perforation in laminates, ceramics, and composite panels for weight reduction, EMI shielding, and airflow optimization.
Permanent UID & MIL-STD 130 Marking
Serialization, QR codes, and MIL-SPEC compliant engraving for complete traceability across defense supply chains.
Multi-Layer & Composite Processing
Laser cutting of bonded structures, sapphire windows, and optical defense systems.
Laser Drilling Engineered for Extreme Aerospace Demands
Laserod’s precision laser drilling is trusted for the most demanding aerospace applications, including propulsion, structural, and sensing systems. Our AS9100 and ISO 9001 certified quality system provides the rigor, traceability, and process control essential for mission-critical manufacturing. We deliver repeatable, burr-free holes with micron-level control to achieve the precision and reliability required for mission success.
Aerospace Laser Hole Drilling Services
Burr-Free Laser Drilling
High-precision drilling for aerodynamic and fluid-dynamic efficiency.
Controlled Diameter Orifices
Flow-calibrated hole drilling in Inconel, titanium alloys, aerospace-grade composites, technical ceramics, and sapphire for precision fluid, cryogenic, and airflow control.
High-Aspect-Ratio Micro Holes
Sub-25um diameter holes with aspect ratios exceeding 20:1 for bleed air systems, thrust vectoring nozzles, missile guidance hardware, satellite propulsion thrusters, hypersonic vehicle cooling channels, micro-fuel injectors, and avionics sensor calibration ports.
Tight Positional Accuracy
±5μm hole placement where positional precision directly impacts mission performance.
Custom Shaped Hole & Slot Drilling
Non-circular and variable-geometry openings for aerodynamic flow control, spray orifice fabrication, laser-cut cooling slots, and multi-aperture.
Capabilities
Laser Types
Femtosecond
1028nm / 514nm / 343nm Wavelengths
Picosecond
1064nm / 532nm / 355nm Wavelengths
Nanosecond
1064nm / 532nm / 355nm Wavelengths
Materials
- Inconel
- Ceramic Matrix Composites (CMC)
- Kapton
- Titanium
- Sapphire
- PTFE
- Stainless Steel
- Silicon Carbide (SiC)
- Aluminum
- Gallium Nitride (GaN)
- Carbon Fiber Reinforced Polymer (CFRP)
- Gallium Arsenide (GaAs)
Specs
- Substrate Size: Up to 700mm x 700mm
- Substrate Thickness: Up to 3mm
- Kerf Width: Down to 10ums
- Hole Diameter: Down to 5ums
- Feature Registration: +/-5ums
Need A Sample?
Every project is unique, but we are confident we can make it work. Send us material and a drawing and we will produce a sample for you.
Looking For More Info?
Most projects we work on are custom. If you’re looking for more information about how Laserod can help with your project, our sales and engineering team are here to assist you.
Key Applications
Fuel Injector Nozzles & Spray Holes
Micro drilled, flow matched spray holes in fuel injector tips to ensure optimal atomization, combustion efficiency, and reduced emissions in turbine engines.
Cooling Holes in Thermal Protection Systems
High aspect ratio cooling holes in ablative shields, ceramic tiles, and heat shields for spacecraft and hypersonic vehicles.
Aerospace Nozzle & Vent Orifices
Precision drilling of vent and purge holes for propulsion systems, gas turbines, and satellite propulsion components.
Waveguide & Antenna Apertures
Ultra-precise slotting and drilling in aerospace grade metals, ceramics, and composites for radar, communications, and EW systems.
Optical & Sensor Apertures
Laser cutting and drilling in sapphire, fused silica, and optical ceramics for targeting systems, cameras, and satellite optics.
EMI/RF Shielding Patterns
High density micro-perforation in thin metal foils for EMI/RF shielding panels, balancing conductivity with precise airflow or signal transparency.
Ignition System Components
Drilling of precision holes in igniters, spark plug electrodes, and laser ignition devices for aircraft and spacecraft propulsion.
Composite Honeycomb Core Cutting
Contour cutting and perforating aerospace honeycomb structures with zero charring or resin pull-out, ready for bonding to skins.
Aerospace Filter & Screen Fabrication
Micro-perforated patterns in stainless steel, Inconel, or titanium for high-pressure fuel and hydraulic filtration systems.
Miniature Fastener & Rivet Holes
Accurate drilling in thin-gauge aerospace alloys for precision fastening, minimizing structural distortion.
Satellite Thruster Components
Micro drilled orifices and cut features in exotic alloys for cold gas or chemical thrusters in small satellites and probes.
Battery & Energy Storage Enclosures
Laser cutting of vent ports and sensor openings in aerospace battery housings, ensuring safety compliance and thermal regulation.
Advantages of Laser Processing
Laser micromachining including both precision hole drilling and laser cutting, delivers unmatched advantages in high performance manufacturing. It offers exceptional control, speed, and material versatility while enabling intricate geometries, tight tolerances, and consistent quality across aerospace, defense, medical, semiconductor, and other mission-critical applications.
Precision and Accuracy
Laser processes deliver extremely tight control over feature size, shape, and placement. For drilling, this means submicron accuracy in hole diameter, depth, and position. For cutting, it enables micron level edge placement and intricate contouring. This precision is essential for microvias, sensor ports, aerodynamic structures, precision apertures, and custom part profiles.
Non-contact Processing
Both laser drilling and cutting are non-contact techniques, eliminating tool wear and mechanical force on the workpiece. This reduces the risk of cracking, delamination, or distortion in delicate substrates such as glass, ceramics, thin films, composites, and high value aerospace alloys.
Versatility
A single laser platform can produce through-holes, blind vias, slots, complex contours, and intricate patterns across a broad range of materials, including polymers, metals, ceramics, semiconductors, and multilayer composites, without changing physical tooling.
Speed
Compared to mechanical or EDM methods, laser drilling and cutting can achieve significantly faster cycle times, especially when using ultrafast lasers and galvo-based scanning. This supports rapid prototyping, short-run production, and high-volume manufacturing.
Flexibility in Design
laser systems execute virtually any geometry from CAD with programmable precision, which can include round, square, tapered, or custom-shaped holes; straight, curved, or highly complex cut paths. This frees engineers to design for performance rather than being limited by conventional fabrication constraints.
Minimal Material Waste
Laser micromachining produces narrow kerfs, minimal burrs, and tightly controlled heat-affected zones. For cutting, this means clean, precise edges with little need for post-processing. For drilling, it results in smooth, accurate hole walls with minimal debris or scrap, which is critical when working with expensive materials.
Quality And Consistency
Digitally controlled parameters and real-time feedback ensure repeatable results across production runs. Whether producing thousands of identical cut parts or high-density hole arrays, laser processes maintain consistent dimensions, surface quality, and functional performance.
Reduced Chemical Usage
Laser micromachining often replaces processes that require chemical etching or wet treatments. Both drilling and cutting can be performed as clean, dry operations, reducing or eliminating the need for harsh chemicals and helping meet environmental and safety regulations.
