Ultra‑high power (UHP) lasers (≥30 kW) enable macroscopic laser‑material processes with markedly different physics compared to conventional systems. By the introduction of high-end fiber laser technology, laser power has become almost infinitely scalable to economically feasible prices.

This study investigates how beam shaping and thus spatial intensity distribution is realized at such laser powers and how it effects key parameters (processing speed, quality and stability as well as power consumption) in three key processes - laser beam welding, laser beam cutting and laser stone drilling - focusing on the lasers, optical systems and finally part quality. We qualify how tailored beam profiles (core-ring spot, multi focus arrangements and fully arbitrary profiles) alter energy coupling, melt‑pool dynamics and keyhole behaviour in UHP regimes.

Results show that optimized beam forms extend stable operating windows, permitting increase in feed rates while reducing spatter and thermal influences when process control is maintained. Conversely, aggressive power scaling without appropriate beam control degrades stability and surface quality.

We identify critical control parameters and their quantitative influence on penetration depth, material removal rate and defect formation, and outline required monitoring and feedback strategies to preserve quality at high throughput. The findings provide a compact framework linking beam shape to process performance for industrial adoption of UHP lasers.