Calibrated Flow for Leak Testing

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Lenox Laser utilizes laser ablation of micro holes in glass and plastic bottles. Our process is fast and easily repeatable way to calibrate leak test equipment by laser drilling precision small holes directly into packaging and bottles. Our experts at Lenox Laser pioneered the process for laser drilling calibrated holes used today. We have the ability to drill directly into IV bags, ampoules, blister packs, aerosol cans, glass bottles, and syringes. The process is so precise we can laser drill clean holes less than 1 µm. Lenox Laser is currently in the process of complying with the ISO Standard 17025. Industries today can not risk the integrity of their packaging structure, it affects their customers which affects the trust they have built.  Trust Lenox Laser with the most precise way to perform leak testing.

What Is Laser Drilling?

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Laser drilling is technology of choice when looking to drill small, precise, and clean holes. Laser drilling refers to the process of creating popped or percussion drilled holes.These micro holes can be laser drilled down to a sizes of .5 microns when measured optically and .3 microns when measured using flow calibration. It is a great alternative to standard mechanical drilling, broaching, and punching. Through laser drilling a wide range of hole diameters are achievable. It is especially useful when drilling holes with a large depth to diameter ratio (high-aspect ratio holes). Our processes of laser drilling are easily repeatable and ideal for high volumes of production.

This diagram shows the difference between our pioneered ablation process and the old style of laser drilling.
This diagram shows the difference between our pioneered ablation process and the old style of laser drilling.

Lenox Laser specializes in laser drilling apertures, orifices, slits, shapes, and apodizers in most materials, dimensions, and arrays. For a list of some of the materials we can easily laser drill, click here.

Drilling and Flow Calibrating Small Holes Down to One Micron in Diameter

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Lenox Laser, Inc. drills and flow calibrates small holes from one micron in diameter to six thousand microns in diameter. After flow calibrating, these orifices have a flow diameter that can be used with simple fomulae to accurately predict flow rates through them for any gas or mixture of gases under various pressure and temperature conditions. The shape of the hole has no bearing on the flow diameter thus has no negative bearing on the degree of flow control accuracy.

Flow calibrated holes have found many customer uses over the last thirteen years. They have replaced many other flow control and measuring devices used by industry. They have proven to be less costly, trouble-free and more accurate in almost all cases. These holes are drilled into many different parts and materials, such as, VCR blind gaskets, tubes with a closed end, closed pipe nipples, set screws, and many other custom shapes. The majority of holes that are drilled are in stainless steel, however, many other materials, such as, plastic, glass, and most metals are also in demand.

Let Lenox Laser help you solve your flow control and other flow related problems in an economical and precise way. For more information and technical support call 410-592-3106 or visit our website at

Lenox Laser Flow Certifications

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Our methods of testing and calculating are new and unique. Our testing methods and our calculating methods will be described in a three page description included with this explanation.

Basically all test methods described depend on comparing a part being tested to one of our standards. We have over one-hundred standards which were developed by test method number one. While developing standards a certified digital test gauge that reads in absolute pressures was used to establish and maintain 29.7 P.S.I.A. To establish water volume in the tube or tubes between the lower and upper photocells, water was carefully poured into the system (using an eye dropper), until the lower light came on. Further water was added until the upper light came on. The water added was measured in graduate cylinders and also weighed on a digital scale that read to the thousand of a gram. These volumes with the computer measured time to go from the lower to the upper photocell provided the information to calculate the flow rates and the flow diameters. All tests to establish standards were run a minimum of five times.

In the past, we have sent a few standards to N.I.S.T. test facility for comparison. The first few were midsized and compared within ½ of a percent. The next time we sent some near 5 microns in size and they were found to be approximately ten percent to large. We then sent the same orifices to another N.I.S.T. test facility and they found them to be approximately ten percent too small. They guarantee their test to be within plus or minus seven percent.

We have many repeat customers that have found our work satisfactory over the years. Some of these customers are large and have very sophisticated test equipment of their own. Among these customers is Sandia who gives our quality system an SPQR 1050 certified rating.

All of our standards are re-calibrated yearly. When calibrating parts for customers two separate standards are use to orient the computer. If there is any discrepancy, further testing and checking follows to determine the cause of the problem.
A Lenox Laser certification means we have tested your parts to meet our standards and procedure.

If you need further approval, you can purchase the orifices needed and send them the test facility of your choice.

For more Flow Calibration Certification services, please visit Lenox Lasers certification page.

Test Components with NIST Traceability

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Lenox Laser now offers integrity test components. These components are close-tolerance flow-calibrated micro leak standards for integrity testing for the pharmaceutical industry and have NIST traceability. Standard sizes include, but are not limited to, 1um, 5um, 10 um, 15um, 20 um, 25um and 50 um, with measured flow rates of .02 sccms to 43 sccms at 15 psig of air test pressure.

Lenox Laser’s catalog of flow-calibrated orifices can be found at Flow Orifices – Lenox Laser.
Please visit Calibrated Micro-Leaks – Lenox Laser for more information on micro leaks for integrity testing or call 410-592-3106.

Arrays with millions of small micron holes

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Lenox Laser has once again pioneered a new small hole drilling capability. We are now able to drill arrays with millions of micro holes down to 1 micron in size. We are able to drill in a myriad of materials (Tungsten, Moly, Stainless Steel, Silicon) with spacing down to 15 microns. The hole sizes, shapes, and spacing can all be customized per your application. Some ground breaking applications include nozzles, lab on chip sensors, DNA analysis, beam shaping, and CMOS biotechnologies.


Please check out our Scanning Electron Microscope(SEM) photos showing a sample of our arrays.


0.5 micron in Molybdenum




Lenox Laser’s 30th Anniversary Year Brings More Industry Breakthroughs.

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We have been pretty busy this past year- here is a quick update on a little of what we have been doing!

Not only has Lenox Laser set the standard for sub-micron hole drilling repeatability, but we also do it fast. We can now produce over 1 million holes per hour, setting a new record in laser drilling . That may be more holes (total) than we have drilled in our 30 years of operation.

Nobel Physics Prizes and 2nd International Light Seminar

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2nd International Light SeminarFrom left to right: Joseph d’Entremont, Alex Dudelzak, Greg Solyar, John Mather, and Reza Sarhangi

Earlier this month, on October 4, we had Dr John C Mather speak at our 2nd International Light Seminar. He received the Nobel Prize in Physics in 2006 for his part in the COBE mission regarding the Big Bang theory and the expansion of the universe.

On that very day, the Nobel Prize in Physics was given to another group of scientists also doing work on dark matter and the expansion of the universe, showing that it was in fact rapidly expanding, not slowing down as previously thought. You can read more about this year’s Nobel prize in their press release here. Dr Mather alluded to the recent prize and their work in his talk since it related specifically to the things he has studied. For Dr Mather’s talk, visit our website and click on “Light Seminar”, or click here.

The Archimedes Palimpsest and Lenox Laser

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Lenox Laser, as mentioned in the previous post, is involved and relevant to current events such as the recent Nobel Prize in Physics and the James Webb Telescope.

Archimedes Palimpsest
Photo from the Walter’s Flickr site, part of the Lost and Found exhibit about the Archimedes Palimpsest

Another example is the Archimedes Palimpsest at Baltimore’s Walters Art Museum. It is on a special exhibit right now until January 2012, and, believes it or not, Lenox Laser was involved with this as well! Lenox Laser was involved in the key science that allowed them to see past the monk’s writings and read Archimedes’ instead. SLAC was the organization that was heading up the research to better read the obscured text, and they contacted Lenox Laser for the special tungsten part.

From our earlier blog post about the Archimedes Palimpsest from 2006- it explains Lenox Laser’s key role.

The Archimedes Palimpsest writings lingered unseen for centuries, seemingly purged from the documents forever, until Professor Heiburg began to review small scrawls beneath the visible text. At SLAC, a revolutionary modern analysis of the writing medium has been made – revealing they do contain historically important information left behind by Archimedes, Hidden from the naked eye.When confronted with an engineering challenge involving their Synchrotron X-Ray source, SLAC issued a request to Lenox Laser to produce microscopic laser-drilled holes in thin Tungsten film. These small apertures would prove critical to the team’s success in uncovering the Palimpsest’s “hidden treasure”.

Here is the website about the ancient text:
and the Walters Art Museum:

2nd International Light Seminar

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Yesterday was our 2nd International Light Seminar, and it went very well! Everyone enjoyed themselves and learned something new. The keynote speaker, Dr John C Mather, arrived just before lunch and graciously spent the rest of the afternoon with us. We are in the process of downloading the pictures, video, and other material and will be posting them on here and our Flickr site as soon as we can.

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