Work

CO2 Laser Micromachining of PTFE-Based PCBs: Predictive Modeling of Kerf Depth Through Design of Experiments

Year: 2026

Type: article

Abstract: The escalating demand for miniaturization in electronics necessitates advanced laser micromachining for precise micro-via fabrication in PTFE-based PCBs. This study addresses challenges in controlling CO2 laser kerf depth in PTFE, a material known for properties that complicate material removal. Employing a two-level full factorial Design of Experiments, the effects of number of loops, aperture, and pulse duration were systematically investigated. This analysis revealed that while pulse duration statistically impacted ablation depth, the number of loops was operationally most critical due to its direct proportionality with kerf depth in PTFE, leveraging its low thermal conductivity. Aperture, defining the laser spot size, was often constrained by PCB geometric specifications. The predictive models developed demonstrated robust generalizability across different PTFE-based laminates. Validation of the production of PCBs achieved a 100% success rate in meeting geometric tolerances and surface integrity. This DoE-based framework establishes a process window, significantly reducing parameter identification time and scrap, thereby enhancing manufacturing yield.

Source: Micromachines

DOI: 10.3390/mi17040404

Authors: Giorgio Pellei, Paolo Di Stefano, Luca Mascalchi, Renzo Centi

Institution: University of L'Aquila

Language: English

Topic: Laser Material Processing Techniques

Subfield: Computational Mechanics

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: gold

Estimated APC paid: $2,534