Laser-drilled filters and screens for industrial filtration processes
Reliable filtration for high flow rates and challenging materials
What are the challenges of filtering and screening with micro-perforations?
In many industrial filtration processes, such as material processing for the recycling industry, filters and screens play a central role: They remove particles and contaminants from the material stream, thereby safeguarding the quality of the end product and the stability of downstream processes.
However, high throughput rates, varying material qualities, and abrasive particles place high demands on filtration systems.
Typical challenges in the manufacture and application of industrial filters:
- Uneven filtration due to imprecise or varying pore sizes
- High pressure losses in the process, especially at high flow rates
- Rapid wear of filter structures caused by abrasive particles
- Uneven flow distribution within the filter
- Short filter service life
- Fluctuating quality of the final material
- Laborious filter changes/maintenance and plant downtime
- High material losses due to insufficient separation of contaminants
- Limited precision of conventional manufacturing processes for very small holes in the micrometer range
- Limited design freedom regarding hole diameters and hole geometries
- Clogging of filter openings by fine particles
Traditional manufacturing processes for filter structures quickly reach their limits, especially when dealing with high throughput rates, fine particle sizes, and heavily contaminated material streams.
Our Solution: Filter holes created by laser machining
Laser processing enables the production of high-precision holes in metals for filter and screen applications, such as those used in the recycling industry. Even very small hole diameters and high hole densities can be achieved with consistent results—a key requirement for stable filtration processes.
Compared to mechanical manufacturing processes, laser processing offers significant advantages for the production of modern filter structures:
- Contactless & burr-free machining with no tool wear
- Precisely defined hole diameters down to 100 µm and tight tolerances
- Reproducible filter geometries
- High hole densities for efficient filtration
- Flexible adaptation of hole patterns and filter designs
- Machining of all metals
- Uniform flow distribution thanks to precise, burr-free micro-drilling
- Longer filter service life and more stable process conditions
This allows filter systems to be tailored specifically to the requirements of demanding filtration processes—for example, in material reconditioning, polymer processing, or powder processing.
Your advantages of laser-drilled screens for filtration processes
Quality
Precise microscopic holes increase filtration performance and improve material quality
Process Reliability
Uniform filter holes ensure stable pressure ratios and reliable filtration results
Fexible Filter designs
Complex perforation patterns can be precisely and digitally adapted to different materials and recycling processes
Lifespan
Precise micro-drilling reduces uneven stress and extends the service life of the filters
MACHINE SOLUTION for precise laser drilling of filtration systems
Pulsar Photonics has developed a specialized line of laser systems for the industrial processing of filter plates and screens.
The RDX2Drill laser machine enables the precise automated laser drilling of large numbers of holes in filter structures.
- Processing area up to 400 mm x 400 mm x 400 mm
- Material thickness up to 1.5 mm
- Drill hole diameter 100 – 400 µm
- Drilling system for single-pulse drilling with high-power QCW fiber lasers
- Integrated extraction unit for removing molten particles
- Implementation of any drilling pattern
- Application-specific software solution
- Precise component positioning & process monitoring
Where filters and screens
are typically used
Industrial filter and screening systems are used in various areas of material processing. Examples:
- Recycling industry
- Metal powder processing
- Battery materials
- Chemical suspensions
- Smelter filtration
- Powder processing
- Granule production
- Plastics processing
- Powder handling for additive manufacturing
Our Products & Services
Laser Machines
Mechanical engineering for laser material processing. State-of-the-art laser systems for custom manufacturing and automated mass production.
Laser Contract manufacturing
Component manufacturing and machining using ultrashort-pulse lasers. Feasibility studies, process development, and contract manufacturing through to series production.
Feasability studies & Process development
At the Pulsar Laser Application Center, filter designs and processing methods can be developed and tested in collaboration with our clients.
- Feasibility studies for new applications
- Tests using different raw materials
- Development and optimization of filter designs
- Evaluation of quality, precision, and process stability
- Process validation prior to series production
- Development from prototype to series production
You have a question About a product?
Your Contact Person for sales
Louisa Draack
Technical sales
The company: Why choose Pulsar Photonics?
- Extensive experience in laser micro-machining
We have extensive experience in developing industrial laser processes for precise microstructures and holes in a wide variety of materials - Development, automation, and systems engineering from a single source
From process development to the finished automated production system, we support our customers every step of the way toward industrial implementation - Process development in our own laser application center
New applications and components can be tested in our laser application center and further developed in collaboration with customers - Solutions for industrial series production
Our systems are specifically designed for stable processes, high-volume production, and integration into automated production environments
