Laser milling as a ‘rapid’ micromanufacturing process

Abstract Laser milling involves applying laser energy to remove material through ablation in a layer-by-layer fashion. Computer numerical control (CNC) programs for laser milling are obtained directly from a three-dimensional computer aided design (CAD) model of the workpiece. Thus, apart from being a material removal rather than a material accretion system, a laser milling machine operates like any other layered manufacturing technology equipment. This paper reviews the physical phenomena underlying the interaction between a laser beam and a workpiece and the mechanisms governing the ablation process with a view to identifying the key process parameters. The paper then focuses on the use of laser milling to manufacture small parts rapidly in materials that are difficult to machine by conventional means.