Nanosecond multi-pulse laser milling for certain area removal of metal coating on plastics surface

•Laser milling was applied for removing of metal coating on plastics surface.•Generation mechanism and avoidance strategy of the processing defects are studied.•An accurate prediction model for the laser milling depth is proposed.•The proposed approach is suitable for machining micro-strip antenna etc.

Metal coating with functional pattern on engineering plastics surface plays an important role in industry applications; it can be obtained by adding or removing certain area of metal coating on engineering plastics surface. However, the manufacturing requirements are improved continuously and the plastic substrate presents three-dimensional (3D) structure—many of these parts cannot be fabricated by conventional processing methods, and a new manufacturing method is urgently needed. As the laser-processing technology has many advantages like high machining accuracy and constraints free substrate structure, the machining of the parts is studied through removing certain area of metal coating based on the nanosecond multi-pulse laser milling. To improve the edge quality of the functional pattern, generation mechanism and corresponding avoidance strategy of the processing defects are studied. Additionally, a prediction model for the laser ablation depth is proposed, which can effectively avoid the existence of residual metal coating and reduces the damage of substrate. With the optimal machining parameters, an equiangular spiral pattern on copper-clad polyimide (CCPI) is machined based on the laser milling at last. The experimental results indicate that the edge of the pattern is smooth and consistent, the substrate is flat and without damage. The achievements in this study could be applied in industrial production.