Laser Microperforations in Aluminum for the Development of New Aesthetic Finishes with Backlighting

What was the challenge or problem to solve?

In the current industrial world, there are constant challenges to improve the aesthetics and functionality of products. The materials team faced one of these challenges, focusing on creating laser microperforations in laminated aluminum.

The goal was to achieve a backlighting effect through these perforations, which in turn should be practically invisible to the human eye when the system is off. This challenge arose in response to a market need where existing backlighting techniques did not fully meet the required aesthetic and functional demands.

Laser Microperforations in Aluminum for the Development of New Aesthetic Finishes with Backlighting

The project focused on creating holes small enough to be imperceptible to the naked eye. These holes needed to be less than 50 microns at the exit, ideally below 25 microns, to ensure their invisibility. Additionally, critical aspects such as minimizing oxidation and eliminating burrs and splashes, which could affect the quality of the final result, had to be considered. The success of the project was defined by the ability to achieve microperforations that allowed light transmission without the holes being visible.

How was it addressed or what was the solution?

To tackle this challenge, INFINITIA’s Materials Innovation team conducted an extensive literature review to determine the optimal size of the holes, considering the final application of the pieces and the limits of human visibility. A state-of-the-art ultrashort pulse laser was selected, as it offered superior quality in micro perforation and high absorption, essential for achieving quality holes without burrs or oxidation.

The choice of material was also crucial. Laminated aluminum, widely used in the sector and suitable for acting as an illuminable interface when microperforated, was chosen. The experimental phase involved designing tests to explore the capability of the selected laser, using different modes of pulse exposure, and its interaction with the aluminum.

To ensure precision, optical microscopes were used to measure the dimensions of the perforations and analyze the light transmission through them. Additionally, a Scanning Electron Microscope (SEM) was used to observe the interior of the holes and detect possible defects.

Microperforations were achieved that met all the client’s aesthetic and functional requirements. This project not only solved a complex technical problem but also opened new aesthetic possibilities for the client’s future applications.