Laser machining platforms have been used in prototyping for years, as set-ups are fast and high levels of accuracy can be achieved — plus there is no physical tool or tool wear to affect accuracy and repeatability.

However, laser prototyping for micro-parts is more challenging, as thermal damage (by way of melting, burning or the creation of a recast layer) in the heat-affected zone (HAZ) will affect the quality and accuracy of microscopic parts.

That said, using ultra-fast lasers with pulse widths in the femto-second range, thermal damage can be avoided, enabling ‘flawless’ micro-part prototypes to be made.

Until recently, femto-second lasers were not robust enough for full-scale manufacturing, but that has changed in recent years, with the advent of commercial-grade femto-second lasers and manufacturing platforms that offer the stability, part handling and beam control necessary for repeatable precision material removal on micro-parts in a 24/7 manufacturing environment.

Examples of next-generation designs that have moved from prototypes to finish-manufactured parts using femto-second lasers include OLED (organic light-emitting diode) panels, fuel injector nozzles, and medical devices such as coronary stents.

The ML-5 from Coventry-based GF Machining Solutions Ltd (www.gfms.com/uk) is a market-leading ultra-fast laser-based micro-machining platform that combines “exceptional” part-handling, motion control and real-time positional feedback to deliver perfect micro holes and other features in seconds.

It features a five-axis laser scan head, a precision-ground natural granite base, iron-less linear motors, Heidenhain glass scales, and automatic palletised work-holding to deliver the precision and performance required for machining at the micro level.

Moreover, the ML-5’s femto-second laser makes it possible to machine a wide range of materials without creating any HAZ — thereby ensuring part quality, high surface finishes and sharp edge reproduction; it can also create unique shapes that are beyond the scope of conventional machines — including negative taper holes, holes that change shape (circular entrance and elliptical exit) and star patterns.