Unlocking Precision and Possibilities with Laser Drilling

In the world of advanced manufacturing and technology, there’s a remarkable process that has been making waves – laser drilling. This micro drilling with lasers has proven itself to be a game-changer, enabling the creation of microscopic holes in a variety of materials, including ceramics, polymers, metals, and even silicon chips. But what sets laser drilling apart, and how does it revolutionize industries ranging from space exploration to semiconductor manufacturing? Let’s delve into the incredible world of laser drilling and its far-reaching impact.

The Science Behind Laser Drilling

At its core, laser drilling relies on a process known as controlled ablation. This involves the precise removal of material through exposure to high-intensity laser irradiation. The result? Minuscule holes with astonishingly small diameters, some as tiny as 1/2 of a micron, achieved with sub-micron placement accuracy. This level of precision opens doors to a myriad of applications across various sectors.

Space Exploration Takes Flight

One of the most awe-inspiring applications of laser drilling can be found in the field of space exploration. The James Webb Space Telescope, often heralded as the next giant leap in astronomical observation, relies on laser-drilled precision. In particular, laser drilling plays a pivotal role in creating precise alignment targets for the telescope’s infrared imaging system.
This incredible system is designed to study the universe’s most distant and enigmatic celestial bodies, such as its first galaxies, stars, and planets. Thanks to the accuracy and reliability of laser-drilled alignment targets, the telescope can capture the cosmos in unprecedented detail, unraveling mysteries that have captivated scientists and stargazers for generations.

Empowering Silicon Chips

But laser drilling’s influence doesn’t stop at the edge of the Earth’s atmosphere. It extends deep into the heart of modern technology – silicon chips. In the semiconductor industry, laser drilling is instrumental in creating internal circuit interconnections within these microelectronic powerhouses.
As the demand for smaller, faster, and more powerful silicon chips continues to grow, the quality and throughput requirements for laser drilling have never been more critical. With laser technology, manufacturers can meet increasingly stringent tolerances regarding dimensional and positional specifications, ensuring that the electronic devices we rely on daily perform at their best.

A World of Opportunities

The power of laser drilling lies not only in its precision but also in its versatility. It’s a driving force behind advancements in various fields, from space exploration to semiconductor technology. The ability to create minuscule, accurate holes opens doors to limitless possibilities, shaping the way we explore the universe and pushing the boundaries of technology.
As technology continues to advance, we can expect even more remarkable applications for laser drilling to emerge. The quest for precision, accuracy, and efficiency remains at the forefront of innovation, and laser drilling is poised to be a key player in this exciting journey. The future holds endless opportunities, all thanks to the tiny holes created by this remarkable process.
At Lenox Laser, we believe the world of laser drilling is a testament to human ingenuity and the desire to explore, create, and innovate. It serves as a shining example of how a seemingly small process can have an astronomical impact on our understanding of the cosmos and the devices we use in our everyday lives. So, keep an eye on those microscopic holes – they might just hold the key to the future.
For more information on laser drilling and its applications, stay tuned to our website and join us on the journey of discovery and innovation.

Lenox Laser to Unveil Precision Innovations at 2023 Mid-Atlantic Design-2-Part Show

OAKS, PA • NOVEMBER 8 & 9 — Lenox Laser, a trailblazer in precision innovation, is eagerly preparing to showcase its cutting-edge solutions at the 2023 Mid-Atlantic Design-2-Part Show. This dynamic two-day regional trade show, organized by The Job Shop Company Inc., serves as a convergence point for contract manufacturers, job shops, and industry leaders spanning diverse sectors.

Lenox Laser’s Precision Showcase:

• Small Holes, Big Impact: Since its establishment in 1981, Lenox Laser has specialized in crafting small holes, intricate slits, and complex shapes across a wide spectrum of substrates.
• Flow Control Expertise: Their mastery extends to flow control orifices, available in both standard Swagelok® fittings and customized applications. These orifices range from thousands of microns down to an astonishing 0.5 micron.
• Quality Assurance: Lenox Laser’s unwavering commitment to quality aligns with stringent standards set by the National Institute of Standards and Technology (NIST), ensuring consistent and reliable performance at specified flow rates.

Cutting-Edge Lasers and Beyond:

• Lenox Laser has an array of cutting-edge lasers that feature ultra-fast, ultra-precise lasers coupled with cutting-edge software, enabling them to work with an extensive array of materials and thicknesses for bespoke needs.

Materials Expertise:

• Lenox Laser’s track record includes working with materials such as silicon, Valor® Glass, titanium, stainless steel, nickel, and polycarbonates.
• Beyond microhole drilling, they excel in laser processing for custom projects.

Meet Tom Hoffman and His Team at Booth #444:

• Tom Hoffman, General Manager at Lenox Laser, invites you to engage with his team of engineering experts.
• Explore innovative solutions and witness the future of laser technology firsthand.
Event Details:
• When: November 8 & 9, 2023
• Hours: Wednesday 9:30 am – 3:00 pm | Thursday 9:30 am – 3:00 pm
• Where: Greater Philadelphia Expo Center
o Conveniently located in the Northwest Philadelphia suburb of Oaks (Phoenixville)
o Easy access from 8 major highways
o Plenty of free parking, avoiding big city hassles


Lenox Laser is committed to ensuring the integrity of container closure systems in pharmaceutical and critical packaging. As part of this commitment, we adhere to the latest Container and Closure System Integrity Testing (CCIT) guidelines.
These guidelines, established by the FDA, recommend methods other than sterility testing to confirm container and closure system integrity. They apply to sterile biological products, human and animal drugs, and medical devices. Here are the key points:

Purpose and Scope:

  • The guidance provides recommendations for manufacturers.
  • It emphasizes using alternative methods to sterility testing for confirming container and closure system integrity.
  • These methods are essential components of stability protocols for sterile products.

Why CCIT Matters?

  • Federal Standards: Compliance with federal standards is crucial to prevent widespread damage to products and ensure public safety.
  • Reliable Testing: Companies need reliable methods to identify defects that compromise product integrity.
  • Calibration Assurance: Ensuring that machines detecting imperfections are correctly calibrated is vital.

What’s Lenox Laser’s Role?

  • Leak Detection Reliability: We contribute to the reliability of leak detection processes.
  • Calibrated Leaks: By intentionally introducing calibrated leaks using our products, pharmaceutical companies can monitor and verify that their systems meet quality standards.
  • Precision and Accuracy: Our proprietary laser drilling and flow calibration processes allow us to create orifices on a micron and sub-micron scale in various packaging materials.
  • Custom Solutions: We tailor our processes to accommodate specific requirements.

For inquiries about our capabilities or to request a custom CCIT job quote, feel free to reach out. Unsure about the orifice size you need? Check out our custom orifice calculator on our website.

Humanity’s First Interstellar Space Flight is Powered by Lasers

Space provides us with endless opportunities to explore the vastness beyond our atmosphere. However, escaping the gravitational pull of Earth has proven difficult. Scientists may have come up with a solution to this problem by asking: instead of flying into space, what if we could sail there? Researchers working for the company Breakthrough Initiatives are developing a method of space travel utilizing modified solar sails to capture laser light to provide propulsion. The project, dubbed Breakthrough Starshot, is testing this method by sending a probe weighing about 1 gram to Proxima Centauri b in approximately 20 years. By contrast, traditional chemical rockets would take thousands of years to travel the same distance. To achieve this, the probe will be propelled to 20% the speed of light by a 100GW, 1km square array of lasers. The sail attached to the probe captures this laser energy and is pushed by the force it generates, like a traditional sailing ship using the wind. 

Researchers Ho-Ting Tung and Artur Davoyan wondered if similar methods could replace our current chemical and electric rockets in the future. Calculations showed that even a probe powered by a much smaller 1m square, 100kW laser array could far exceed the current record for velocity, with minimal exposure time, in the range of hours to minutes. The team landed on silicon nitride or boron nitride as the best material for the sails due to their high reflectivity and cooling capabilities. They speculate that probes like these could easily be maneuvered between earth orbits within a day, a feat not possible with traditional propulsion methods. They also calculated that the probes could travel fast enough to escape our solar system, reaching up to 5 times the speed of the New Horizons probe.  

If you want to learn more about the Starshot project, click here, to read the original article. 

Or, click here, to read about the project on Breakthrough Initiatives’ website. 

Click here, for past Lenox Laser posts about space exploration. 

Recent Study Verifies Vacuum Decay Method for Detecting Packaging Leaks

Lenox Laser was recently involved in a study dedicated to testing the viability of an ASTM standard Vacuum Decay method of detecting leaks as put forth in their Abstract:

Preface: Vacuum decay, an ASTM standard method (F2338-09) has been well known in the industry as a reliable leak detection method for flexible non-porous pouches, as described in section 3.2.3i. Because the method-study for precision and bias has not been performed yet, as stated in section 1.2.5,ii this sometimes raises questions and doubts on the method itself. This paper can help to take away these questions and/or confusion/skepticism and provide some best practices and steps for product validation. To validate the vacuum decay method on flexible pouches, the most reliable ways are using capillaries or using a micro calibrator. Other methods might be cheaper, but cannot give reliable and reproducible results. In order to calculate flow rates, the Hagen-Poiseuille formula is explained. Moreover, the assumptions and limitations of this formula are covered.

Jobse, Pim & Renema, Andro. (2021). Verifying the Vacuum Decay Method with artificial leaks on flexible pouches.

If you are interested in learning more about this study, you can request the full-text PDF here.

Do you want more information about Lenox Laser’s involvement in the CCIT process? Visit our services page.

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