Laser micro-hole drilling is a core capability at Potomac Photonics. We specialize in producing precise, repeatable micro-scale holes and continually develop new processes to push feature sizes smaller — down to 1 micron, depending on material and geometry.
Our engineering team works closely with customers to fully understand micro-hole requirements, including material type, part thickness, hole diameter, taper, edge quality, and feature geometry. Based on these factors, we recommend a drilling approach that supports both rapid prototyping and scalable production.
Key Considerations for Micro-Hole Drilling Projects
Several factors must be evaluated when planning a micro-hole drilling project. These include material thickness, hole diameter, edge quality, hole shape, taper, and the required center-to-center spacing between holes. Each of these parameters directly impacts process selection and achievable results.
Potomac continually develops and adds new hole-drilling processes to its facility. Our capabilities include multi-axis drilling systems for angled and shaped holes, as well as high-speed setups designed to drill thousands of holes quickly and repeatably. We support material thicknesses ranging from ultra-thin films to components several millimeters thick.
Process Selection and Technology
The drilling technology used depends on both the material and application requirements. Transparent polymers are often best processed using UV laser sources, while metals and ceramics typically require IR laser systems. For applications that call for larger features or zero taper, Potomac also offers micro-CNC drilling as an alternative.
By maintaining multiple drilling technologies in-house, Potomac ensures each project is matched with the most effective and reliable process.
Materials for Laser Micro-Hole Drilling
Laser micro-hole drilling can be applied across a wide range of materials, but achieving consistent, high-quality results depends on selecting the right process for each substrate. Material properties such as absorption characteristics, thermal behavior, thickness, and reflectivity all influence how the laser interacts with the part. Potomac Photonics works with polymers, metals, and advanced materials, tailoring laser sources and process parameters to produce precise, repeatable micro-holes across diverse applications.
Polymer Laser Micro-Hole Drilling
Potomac routinely drills micro-holes in a wide range of polymer materials, including:
Metal Laser Micro-Hole Drilling
Our laser micro-hole drilling capabilities extend across many metals and alloys, including:
In addition to polymers and metals, Potomac Photonics also laser drills micro-holes in other materials, such as ceramics, glass, silicon wafers and other advanced substrates.
Laser Micro-Hole Drilling Experience
Our micro-hole drilling experience includes (but is not limited to):
Leak Test Hole
We specialize in advanced laser drilling technology for container closure integrity (CCIT) leak testing. Our precision laser systems create micro holes from 2 µm to 100 µm in materials like glass, plastic, and metals, ensuring accurate and reliable CCIT.
Our ISO 13485:2016 certified processes guarantee high quality and rapid turnaround times, often completing projects within a week.
Our versatile capabilities allow us to handle various package types and materials, providing flexible and efficient testing solutions to meet your needs.
Probe Cards
Our advanced laser technology at Potomac Photonics enables the drilling of micro-holes as small as 2 microns, with tight positional tolerances required for demanding probe card applications. We routinely work with polymers, ceramics, and other engineered substrates, applying process controls that support consistent feature size and accurate hole placement.
We also provide complete solutions that address larger hole requirements used for probe card assembly, alignment, and orientation, allowing customers to consolidate multiple drilling needs within a single, integrated manufacturing process.
Catheter Micro-Holes
Extremely tight tolerances on hole diameter and position are critical for optical fiber connectors and alignment devices.
Utilizing the latest laser technology and high precision Aerotech stages that are calibrated to a NIST-traceable standard, we are able to meet or exceed the requirements of some of the most challenging fiber optic applications.
In addition, we continue to improve our capabilities to drill thicker materials that are often required for placement of fiber optics with diameters of 125 microns and greater.
GALLERY
Need Additional Microfabrication?
Potomac offers generous incentives to our customers that combine laser micro-drilling services with our exhaustive list of other microfabrication processes.
Also From the Goodfellow Group
Achieving consistent micro-hole quality depends as much on the substrate as the process. Goodfellow offers metal sheet, polymer film, and ceramic plate in tightly controlled thicknesses and tolerances, ready for micro-drilling.
Source your drilling substrate from Goodfellow.
Hole diameter, roundness, wall quality, and subsurface integrity can be independently verified through Goodfellow’s ISO 17025-accredited materials testing division, using SEM imaging and dimensional analysis.
Validate drilled parts before integration into your assembly.
