Femtosecond Laser Spinneret Drilling: How to Achieve Precision Microhole Machining?

From nylon and polyester clothing in daily life to high-performance filtration materials in industrial fields, synthetic fibers are ubiquitous. Behind these fibers lies a critical component: the spinneret. And when it comes to precision microhole drilling in spinnerets, femtosecond laser technology stands out as a game-changer.

Spinneret Machining Challenges & Femtosecond Laser Solutions

Spinnerets—typically made of stainless steel, gold-platinum alloys, or other metals—feature thousands of tiny holes. In melt spinning (the core process for synthetic fibers), molten materials are extruded through these holes to form continuous filaments. Thus, the precision, shape, and surface finish of spinneret microholes directly determine fiber diameter, morphology, and performance.

As demand grows for ultra-fine fibers (e.g., <1 denier), spinneret holes must reach micron or submicron levels. Traditional methods—micro-punching, mechanical drilling, EDM—struggle with microholes or irregular shapes. This is where femtosecond laser precision drilling excels: it crafts custom hole shapes to meet diverse needs.

Femtosecond Laser Advantages in Spinneret Microhole Drilling

1. Superior Surface Finish for Smooth Fiber Output

Rough microhole walls or burrs in spinnerets can cause clogging, disrupt spinning flow, or even break fibers. Femtosecond lasers use "cold machining"—no thermal melting or recasting—resulting in ultra-smooth walls and edges (burr-free, slag-free). Mono Laser’s expertise even achieves R-angle <10μm for specialized applications.

EDM vs. Femtosecond Laser: Microhole Surface Comparison

Femtosecond Laser-Machined Triangular Holes with Rounded Chamfers

2. Ultra-Precision & Miniaturization Beyond Traditional Limits

Femtosecond lasers redefine spinneret manufacturing with 4 key capabilities, outperforming traditional tech:

· ±1μm Precision: Consistent hole diameters, even in large microhole arrays.

· Submicron Sizes: Drills holes as small as tens of microns (aspect ratio <10:1) for ultra-fine fibers.

· High Efficiency: Up to 2000 holes/second—far faster than EDM.

· 99% Roundness: Ensures uniform fiber cross-sections, critical for quality.

Femtosecond Laser: Unlocking Irregular Spinneret Holes for Functional Fibers

Wondering how to machine complex shapes like three-lobe, star, or C-shaped holes? 5-axis femtosecond laser systems—equipped with high-speed scanners and multi-axis control—enable precise laser path planning. The ultra-short pulses vaporize material point-by-point, forming custom 2D/3D holes without contact.

This flexibility lets engineers adjust laser angles and beam shapes to craft:

· C-shaped holes: 58μm±1μm width in 0.5mm stainless steel (taper-free, for industrial filaments).

· Three-lobe holes: 120° symmetric lobes (enhances fiber reflectivity, ideal for silk-like fabrics).

· Star-shaped holes: 4–8 radial lobes (5–20μm width, boosts adsorption for filters/sportswear).

· Hollow holes: Annular channels (creates lightweight, insulating fibers for down alternatives).