Multi-layer thin films of metals, metal oxides and polymers are widely used for various applications in industry, including optics, gas/vapor sensors and automotive. Modern complex multi-material systems require specific properties in the micrometre and submicrometric range through multiple manufacturing steps such as cutting, structuring, welding and marking [1].

Lasers provide a unique interaction with materials, resulting in targeted permanent alterations in chemistry, structure, and morphology. For multi-layer films, the optical properties of ultrashort pulse lasers can be customized to optimize the selective coupling and removal of a specific layer [2].

Laser material processing offers rapid manufacturing, high process reliability, and design flexibility. However, to be acceptable in industrial settings, laser manufacturing must provide the quality and safety requirements as well as being economically viable [3].

This study aims to investigate and optimise ultrafast laser–material interactions for the precision cutting of multi-layer electrode films using picosecond pulse lasers. Cutting quality and process efficiency will be evaluated against industrial manufacturing requirements. A range of laser parameters will be explored by using a 10 picosecond, 355 nm Edgewave laser system. Samples will be characterised via surface topography and edge quality analysis. The fundamental mechanisms of beam–material interaction will be discussed, and a Design of Experiments (DoE) approach will be used to assess how key processing parameters influence both cutting quality and energy consumption.

[1] Basu S, editor. http://dx.doi.org/10.5772/intechopen.77490

[2] A. Sassmannshausen et al., https://doi.org/10.1117/12.2648879

[3] A Ö Aydin et al., https://doi.org/10.3390/batteries9110555