The use of alumina ceramic materials in the biomedical and electronics fields is becoming commonplace due to the superior wear and corrosion-resistance properties of ceramic. Orthopedic joint implants now feature ceramic components and alumina acts as a substrate for many thin-film electronic devices. In industrial environments, alumina ceramic is frequently used to manufacture nozzles, dies, seals, and wear plates.

There are two methods for manufacturing alumina ceramic components. The first is to shape ceramic powders and binders into a “green body” and then create any holes or openings in the part before it is fired at temperatures ranging between 700 °C and 1500 °C. The second manufacturing method is to machine—cut, scribe, grind, or drill—the fired alumina. Although difficult to accomplish, machining fired alumina is often necessary for tight tolerance parts due to subtle variations in part-to-part shrinkage during the firing process. 

This application illustrates the quality and ease of machining thin-sheet fired alumina using a Synrad sealed CO₂ laser. As shown in the photo, the part layout consists of 16 individual pieces on a sheet of 0.5 mm (0.02”) thick alumina. With a power level of 100 watts, the four thru holes and rectangle on each part were cut out at a speed of 0.15 meters per minute (6 inches/minute) using a pulse duration of 2 ms at a frequency of 143 Hertz. After cutting, the area between each part was laser-scribed to create a “perforated” line so that pieces are easily separated from each other by snapping along the score line.

The part layout consists of 16 individual pieces
on a sheet of 0.5 mm (0.02”) thick alumina.