Ultra-high-power (UHP) lasers with output powers exceeding 50 kW introduce new regimes in laser–material interaction and significantly extend the operating window of laser materials processing beyond conventional industrial power levels. At these power levels, the interaction between laser radiation and materials changes fundamentally, affecting energy coupling, melt pool dynamics and vaporization behavior.

This paper provides an overview of the fundamental process regimes emerging in ultra-high-power laser processing and discusses how increasing laser power, beam shaping and intensity distribution influence processing speed and quality. Based on these mechanisms, characteristic regimes and their technological potential for cutting, welding and surface processing are discussed.

While these regimes enable significant productivity gains in established manufacturing processes such as high-speed welding, thick-section cutting and high-rate laser ablation, ultra-high-power lasers also open new application domains beyond traditional industrial manufacturing. In particular, laser drilling for mining and deep geothermal energy extraction is emerging as a promising field, where extreme penetration depths and high aspect ratios are required. The high energy densities achievable with UHP lasers allow efficient rock removal and potentially transformative drilling concepts.

By linking fundamental process mechanisms with emerging application fields, this article highlights the technological potential of ultra-high-power lasers and identifies key parameters governing stable and efficient processing across a wide range of applications.