What is the smallest size hole a laser can cut?

Fiber laser cutting machines are known for their incredible precision—but how small is too small? Many buyers, especially in high-tech sectors, are chasing answers around micro-hole cutting. This article will break it down clearly.

A fiber laser cutter can cut holes as small as 0.1 mm, but reaching that precision depends on material, thickness, and machine setup. It’s not always easy—or practical—for every job.

For those of us working with fiber lasers daily, like we do at Kirin Laser, this is more than a theory. Small holes can be a make-or-break for electronics, aerospace, or medical industries. But when the specs get tiny, the variables start stacking up. Let’s walk through the specifics.

What is the smallest hole laser cutting?

Fiber laser machines are powerful and precise—but even the most advanced system has its limits. What’s the smallest hole size you can actually cut?

The smallest hole size achievable with a fiber laser cutter is around 0.1 mm, under ideal conditions. Material type, heat resistance, and thickness all influence this lower limit.

Factors That Limit How Small a Hole Can Be Cut

Material Type and Reflectivity

Some materials, like stainless steel or titanium, respond well to laser precision¹. But others—such as copper or reflective metals—scatter the beam or absorb too much heat, which makes micro-cutting harder.

Material	Laser Cutting Response	Micro Hole Potential
Stainless Steel	Very stable	0.1 mm possible
Aluminum	Medium stability	~0.15 mm
Copper	Reflective	~0.2 mm
Plastics	Depends on melting pt	~0.2 mm

Machine Settings and Beam Quality

A top-tier fiber laser has better beam quality (M² close to 1.0), which helps focus the energy tighter. At Kirin Laser, we typically recommend 20W to 100W models for thin materials. Our machines can reach sub-0.2 mm resolution² with optimized parameters.

Air Assist and Nozzle Size

The nozzle needs to direct the gas without interfering with beam precision. For very small holes, we use micro-nozzles³ paired with low-pressure air assist to stabilize the cut.

Real Example from a Kirin Client

We worked with an electronics manufacturer cutting 0.1 mm holes in thin aluminum foils. After calibrating the laser and upgrading the nozzle system, we achieved consistent clean cuts, reducing their reject rate by 30%.

What is the minimum size for laser cutting?

Now let’s go broader: what’s the smallest shape or detail that a laser cutter can manage, beyond just holes?

For fiber lasers, the minimum cutting width—often called the kerf—is around 0.1 mm. This determines the smallest possible cut feature in any design.

Understanding Kerf and Resolution in Laser Cutting

What is Kerf?

Kerf is the width of material removed by the laser. If you’re cutting a shape with very narrow features, the kerf⁴ defines your lower limit. For fine designs, especially in jewelry or electronics, the kerf size determines detail clarity.

Why Beam Focus Matters

Our fiber lasers use lenses ranging from 63.5 mm to 125 mm focal lengths. The shorter the focal length⁵, the smaller the beam spot size⁶—which means finer detail. But the trade-off is a shorter depth of field.

Focal Length	Beam Spot Diameter	Ideal Use Case
63.5 mm	~0.04 mm	Ultra-fine, thin materials
100 mm	~0.06 mm	General thin-to-mid cuts
125 mm	~0.08 mm	Thick materials

Cutting vs Engraving

Sometimes, tiny features are better engraved rather than cut. If you're not going all the way through, the beam can mark features smaller than 0.05 mm. But this doesn't apply when you need full-through holes or channels.

What is the minimum gap for laser cutting?

A common question from our OEM clients: How small can the gap be between two laser-cut paths without fusing or distorting the material?

The minimum reliable gap between cuts is typically 0.1 to 0.2 mm, depending on material and thickness. Anything less risks melting or distortion.

Gap Tolerances in Fiber Laser Applications

Why Gaps Matter

In industries like microelectronics, decorative cutting, or mesh structures, small gaps are common. But if cuts are too close, residual heat can cause warping or unintended fusion.

Key Variables

• Material Thickness⁷: Thinner sheets handle small gaps better.
• Cutting Speed⁸: Faster speeds reduce heat buildup.
• Pulse Frequency⁹: Higher frequency gives cleaner edges in close proximity.

Material Thickness	Minimum Gap
0.2 mm	0.1 mm
0.5 mm	0.15 mm
1 mm	0.2 mm

Example: Mesh Grid Cutting

We helped a customer create a stainless steel mesh with 0.15 mm gaps for a filtration component. Using a 500W machine and a tight beam profile, we achieved clean separation with no visible burn marks.

What is the minimum size for laser drilling?

Drilling and cutting are not the same. Drilling uses pulsed energy to punch vertically down, while cutting typically traces along a path. So what’s the lower limit for laser drilling?

The minimum drill size with a fiber laser is usually 0.1 mm, but it depends heavily on pulse control, material, and focus depth.

How Laser Drilling Works and Its Limits

Pulse Control is Everything

Laser drilling needs high-frequency, short-pulse settings¹⁰. Nanosecond or picosecond lasers are ideal. At Kirin Laser, we offer systems that can adjust pulse width to drill micro-holes in metals¹¹ without burning edges.

Heat-Affected Zone (HAZ)

Too much heat spreads into surrounding material, creating bulges or discoloration. That's why short pulses and good cooling are crucial.

Parameter	Impact on Micro Drilling
Pulse Width	Shorter = cleaner drill
Frequency	Higher = better control
Spot Size	Smaller = finer detail

Use Case: Electronics Vent Holes

An electronics OEM needed 0.12 mm vent holes in a 0.3 mm aluminum housing. We optimized the machine using a 20W fiber laser with short bursts and nitrogen assist. The results passed both aesthetic and functional tests.

Conclusion

Precision laser cutting¹² isn't just about power—it’s about control. The smallest hole you can cut with a fiber laser is around 0.1 mm, but that depends on many factors: the machine’s beam quality, your material type, and how you tune your parameters.

At Kirin Laser, we’ve helped customers across industries—especially electronics and manufacturing—achieve sub-millimeter accuracy using fiber lasers. Whether you're cutting, drilling, or designing high-detail parts, understanding your machine’s limits and tuning your setup accordingly makes all the difference.

And if you're not sure where your needs fall? Talk to us. We'll help you dial in the specs.