Manufacturing Processes - Fraunhofer ILT

The focus of the manufacturing processes section is on the practical applications of laser technology. This section provides a concise overview of processes such as cutting, welding, drilling, ablation, texturing, polishing and additive manufacturing, as well as key terms relating to process control, material processing and quality assurance. It thus provides a foundation for understanding modern laser-based manufacturing in research and industry.

Laser beam welding	Joining of materials using a focused laser beam..
Laser beam cutting / Laser cutting	Separation of materials through laser energy input.
Laser drilling	Creating holes through ablative laser processes.
Laser ablation	Material removal using short, high-intensity laser pulses.
Laser metal deposition (LMD)	Additive manufacturing process in which metal powder or wire is melted by laser energy and deposited layer by layer onto a component; also known as DED (Directed Energy Deposition), DMD (Direct Metal Deposition) or laser cladding – used for new part manufacturing, coating and repair.
Laser Powder Bed Fusion (LPBF)	Powder bed-based additive manufacturing process in which metal powder is applied layer by layer and selectively fused by laser radiation; the process was significantly developed at Fraunhofer ILT in Aachen and is today one of the most widely used processes for additive manufacturing of metallic components worldwide.
Selective Laser Sintering (SLS)	Additive process for selectively sintering powder materials (plastics, metals, and to a limited extent ceramics) using laser energy; enables complex geometries without support structures.
Laser hardening	Heat treatment of metal surfaces using laser energy to increase hardness.
Laser polishing	Surface smoothing through controlled laser application.
Laser structuring	Creating fine surface structures for functional properties.
Laser soldering/brazing	Joining of components through laser-induced melting of a filler material (solder) at temperatures below the melting point of the base materials – unlike laser welding, where the base materials themselves are melted; particularly suited for temperature-sensitive components in electronics and microtechnology.
Laser marking	Permanent application of text, codes or symbols on material surfaces.
EHLA (Extreme High-Speed Laser Application)	Advanced LMD with drastically increased speed and low heat input.
Laser engraving	Ablative laser process for creating permanent recesses, patterns or lettering in surfaces.
Laser cleaning	Non-contact removal of rust, paint, oxides or contamination by laser ablation – without chemicals or mechanical contact.
Laser coating / Laser cladding	Application of protective or functional coatings on component surfaces using laser; high adhesion and low heat-affected zones.
Remote laser welding	Scanner-based high-speed welding from a large working distance; particularly efficient in automotive and battery production.
Laser micro-machining	High-precision material processing in the micrometer range; used in electronics, medical and semiconductor technology.
Laser sintering	Additive manufacturing process in which powder materials (plastics or metals) are selectively sintered by laser energy; also known as SLS or DMLS.
Process monitoring	Inline acquisition and analysis of process parameters during laser processing for real-time quality assurance.
Kerf width	Width of the material cut produced during laser cutting; key parameter for dimensional accuracy and material usage.
Weld penetration depth	Depth to which the laser beam melts the material during welding; critical for mechanical joint quality.
Feed rate / Scan speed	Speed at which the laser beam moves relative to the workpiece; influences energy input, cut quality and throughput.
Shielding gas	Gas (e.g. argon, nitrogen, helium) used during laser welding or cutting to protect the process zone from oxidation and improve seam quality.
Directed energy deposition (DED)	International umbrella term for additive manufacturing processes in which material (powder or wire) is directed into the focus of an energy source and melted; includes LMD and EHLA.
Laser beam forming	Non-contact bending and forming of components through targeted local heat input by laser – without mechanical tooling.
Laser-based packaging	Use of laser processes for bonding, sealing and contacting microelectronics components and sensors.
Laser machining	Generic term for all laser-based manufacturing processes for machining materials such as metals, plastics, ceramics and glass – from cutting and welding to ablation and structuring.
Material processing	Modification of the shape, surface or properties of a material using laser energy; encompasses thermal, photochemical and mechanical working principles.
Metal 3D printing	Laser-based additive manufacturing of metallic components, e.g. via LPBF or LMD; enables complex geometries and individualized parts directly from CAD data.
Laser polishing	Smoothing and finishing of surfaces through controlled laser energy input; reduces roughness without tool contact, even for complex geometries..
Process development	Systematic development and optimization of laser-based manufacturing processes from laboratory to production readiness; includes parameter studies, simulation and qualification.
Process optimization	Targeted improvement of laser-based manufacturing processes in terms of quality, speed, energy efficiency and reproducibility – increasingly supported by AI.
AI-assisted laser processing	Use of artificial intelligence for autonomous control, regulation and optimization of laser processes in real time; enables adaptive manufacturing and self-learning systems.
Melt Pool	Zone of molten material forming directly beneath the laser beam during welding or additive manufacturing; width, depth and length of the melt pool are critical parameters for seam quality and layer build-up. Inline monitoring of the melt pool (melt pool monitoring) is a key tool in laser-based quality assurance.