The laminated structure of carbon fiber reinforced plastic (CFRP)-Cu-CFRP is an important structure for aerospace radome. The blind holes manufacturing is core process, but there are technological challenges in achieving the exposure of a 10 μm thick copper foil at the bottom of the blind hole. The exact position of the 10 μm thick copper foil within the material’s internal space is unknown, and the uneven heat accumulation and conduction can easily cause burning and damage to the ultra-thin copper foil. To date, there is no publicly accessible literature that documents the execution of this specific process. In this paper, novel variable inner diameter spiral scanning guided by Cu-CFRP interface accurately extracted using cosine similarity (CS) algorithm is proposed to obtain a blind hole with near-zero ablation damage. The similarity of acoustic emission signals generated by laser interaction with Cu and CFRP, as well as thermal accumulation and conduction behavior under different scanning radius, are described. The high-quality blind holes have been successfully drilled, with a large area copper foil exposed at the bottom, while the surface of the copper foil remaining intact without any damage or heat affected zone. Compared with traditional drilling method, the average exposed copper foil area at the bottom of the blind holes is increased by 238.4 % (from 0.464 mm2 to 1.570 mm2). And the average taper of blind hole is reduced by 41.7 % (from 0.470 to 0.274). This method can effectively increase the area of exposed copper foil and reduces the taper of blind holes, improve the welding strength and conductivity of wires in aerospace radomes, thereby enhancing the stealth performance and operational reliability of fighter jets.
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