Laser Machining Research Articles

Experimental investigation of nanosecond laser Machining of 3D printed carbon fiber reinforced polymer (CFRP) composite

Carbon fiber reinforced polymer (CFRP) composites are widely used in automotive and aerospace applications due to their high specific strengths, high fatigue and creep resistance, and excellent corrosion resistance. Additive manufacturing (AM) or 3D printing has opened new ways of manufacturing complex 3D parts using CFRP composites. As a result, researchers have gained interest in the machining or post-processing of 3D-printed CFRP composites. This study aims to investigate the feasibility of using a nanosecond laser for machining single craters or blind holes and slots on 3D printed CFRP samples and understand the effects of important process parameters on feature dimensions, (i.e., crater diameter, slot width, crater/hole depth, and slot depth), heat affected zone (HAZ), and surface quality of the machined features. A 1064 nm wavelength laser system with a focal length of 160 mm was used, whereas the number of pulses, laser energy level, and back-and-forth laser passes are varied. The heat-affected zone is found to be influenced by the laser energy level as compared to the number of pulses. It is found that for the same number of pulses, there is a clear sign of an increase in HAZ with the increase in laser energy level. With the increase in the number of pulses, the hole or slot edge becomes more defined and clearer, whereas the HAZ is mostly determined by the energy level. There is an accumulation of molten or removed materials at the edge of holes or slots causing jagged edges of machined features, which gradually diminishes when the edge becomes smoother for a higher number of pulses, or accumulated materials evaporate away at the higher setting of energy level. Finally, it is found that the nanosecond laser system is capable of machining quality holes and slots on the 3D-printed CFRP composite. To obtain features with well-defined profiles and minimal heat-affected zone, an understanding of the effects of laser process parameters is important.

Laser Beam Machining: A Review on Research Trend

Abstract: Laser Beam Machining (LBM) is an advanced non-conventional machining process that employs a highly focused laser beam to remove material from a work-piece. This thermal-based process utilizes the intense energy of the laser beam to induce localized melting, vaporization, or ablation of the material, resulting in precise and controlled material removal. The process involves key components such as a laser source, optics for beam focusing, and a work-piece mounted in the machining setup. Laser beam machining offers various advantages, including high precision, non-contact nature, minimal heat-affected zone, and the capability to work with a diverse range of materials. The two primary applications of LBM are laser cutting and laser drilling. Laser cutting involves using the laser beam to cut through materials along a specified path, while laser drilling creates holes or openings in the work-piece with great accuracy. The versatility and efficiency of laser beam machining make it suitable for numerous industries, including aerospace, automotive, electronics, medical, and jewellery manufacturing. As a result of its unique capabilities and benefits, LBM continues to play a crucial role in modern manufacturing, enabling the production of intricate and complex components with high precision and quality

LASER MACHINING OF BASALT GLASS HYBRID COMPOSITE USING DEMATEL METHOD

Hybrid composites are materials made of two or more different types of fibers incorporated into a single polymer matrix the year 2019 publication failure analysis in bio composites, fiber-reinforced composites, and hybrid composites. A hybrid composition of basalt and glass layer fabricated and its various mechanical properties after being tested. Glass-fiber composite is a magnificence of fiber-reinforced polymer composites. Hybrid compounds are common ones two or more in the matrix combining different types of fiber products manufactured by various hybrid gave researchers compounds have many definitions. A laser machine is a target material that interacts with a laser beam it is a material removal process done by such a device that uses photon energy processing to the target object thermal or photochemical energy is carried in the form of removing the items directly and by melting evaporation elimination. Commercial, industrial, aeronautical, maritime, and recreational constructions can utilize hybrid composites for their main structural components. It offers a wide range of advantages in the aerospace sector, including strong impact resistance, outstanding fatigue and corrosion resistance, and both. A hybrid composite made of layers of basalt and glass has been created, and after that, its varied mechanical characteristics have been examined. It takes time to precisely machine these composite materials. The mechanical performance of the hybrid composite is decreased by a number of constraints in traditional machining, including fiber pullout, delamination, burr formation, matrix crack development, etc. These issues might result in a poorly machined surface. The decision-making trial and evaluation laboratory (DEMATEL) is regarded as an efficient technique for locating the causal links in a complex system. It focuses on assessing the interdependencies between elements and identifying the crucial ones using a visual structural model. Lamp current (amp), Pulse frequency (Hz), Cutting speed (mm/min), Pulse width (ms), Air pressure (bars). From the result, it is seen that Lamp current got the first rank whereas the Pulse width is having the lowest rank.

Optimization of Laser Beam Machining Process Parameters of HSLA Steel Using MOORA

The current research paper is focused on investigating the influence of Laser beam machining process parameters on surface roughness and kerf width of HSLA steel. Taguchi’s L18 orthogonal array is adopted to conduct the machining studies. MOORA method is used to evaluate the suitable combination of the LBM process parameters. The combined effect of machining performance measures is analysed using analysis of variance to identify the significance of the result. Consequently, the influence of the parameters on machining responses were explored. The surface morphology of the machined surface of the optimal set of parameters has been studied.

Influence of re-deposited nanoparticles on the surface elemental composition of femtosecond laser machined copper surfaces

Nanoparticles re-deposited during the laser machining process have been suspected to modify the intrinsic surface chemistry of machined metallic surfaces. However, only very few studies have focused on elucidating their effect. In this work, under two different machining conditions (laboratory air & controlled humid air), we fabricated laser-induced periodic surface structures, LIPSS, on polished Cu surfaces with three different amounts of re-deposited Cu nanoparticles to quantify how re-deposited Cu nanoparticles affect the surface chemistry of the machined samples. In carrying out these experiments, we demonstrate that the re-deposition of nanoparticles during laser machining is affected by the volume of the laser machining environment, which impacts the surface chemistry of laser-machined surfaces. Our results indicate that evacuation of the vacuum chamber before and after laser machining using a vacuum scroll pump did not affect the adsorption of carbonaceous molecules. Further, we present the effect of removing re-deposited nanoparticles through ultrasonic cleaning on the surface chemistry of the test surface. The cleaning exposes the LIPSS surface entirely to airborne carbonaceous species, resulting in a more significant increase in the total surface carbon content. Finally, we evaluated the quality of the nanoparticles generated during laser machining by assessing their stability to provide a first insight into the utility of those nanoparticles.

Study on anisotropic heat transfer and thermal damage in nanosecond pulsed laser processing of CFRP

AbstractNanosecond pulsed laser processing is an efficient method of processing carbon fiber reinforced plastic(CFRP), which is widely used in the manufacturing field of aviation, medical, and auto industries. The anisotropic heat transfer of carbon fiber is a key factor degrading the surface integrity of laser processing CFRP. So it is urgent to explore the significant mechanism of anisotropic heat transfer of laser interacting with CFRP. A novel numerical model considering anisotropic heat transfer was established to analyze heat transfer and thermal damage of CFRP laser machining. By comparison of simulation and experiments, the average error of ablation depth and width ranges from 4.71% to 15.09%, so the model could precisely simulate the CFRP laser machining. It demonstrates that the heat conductivity along the axial carbon fiber is higher than that along the radial, resulting in an elliptical ablation morphology. And when the laser scanning direction is parallel to the direction of the carbon fiber, deeper and narrower microgrooves can be obtained. In addition, laser processing at the edge of the CFRP plate causes serious heat accumulation, leading to severe thermal damage. The simulation and experiments were conducted to explore the effect of parameters including laser energy, scanning speed, and scanning space on the depth and width of laser ablation. A deeper micro‐channel with a smooth machined surface and small thermal damage was obtained when laser energy E = 0.275 mJ, scanning speed v = 630 mm/s, and scanning space h = 21 μm.

Closed randomized comparative study of great saphenous vein crossectomy laser ablation versus standard laser technique to minimize recurrence in the treatment of primary varicose veins

Background Incompetence at the saphenofemoral junction (SF) is the most common cause (70%) of varicose veins. Endovenous laser ablation (EVLA) uses laser energy to ablate incompetent axial veins selectively and was originally described for the treatment of GSV reflux and its related varicosities. The venous system is a network of interconnected vessels; any preserved inflow of the saphenous-femoral mouth can cause postoperative recurrence. However, according to the literature, the greatest risk of recurrence is associated with the stump of the GSV of venous tributaries, including great venous trunks parallel to the GSV in the thigh. Aim of the work Comparison of the standard endovenous laser ablation technique (1.5–2 cm from SFJ) versus crossectomy ablation for the treatment of varicose veins regarding recurrence of reflux and incidence of endovenous heat-induced thrombus (EHIT) in the first week. Patients and methods In all, 80 patients admitted to Ain Shams University Hospitals and Alexandria Armed Forces Hospital from Jan. 1st, 2021 to Jan. 30th, 2023 participated in the study. The patients were divided evenly into two groups: Participants were randomly assigned to one of the trial groups using the sealed envelope method.Group A was treated by ablation of the great saphenous vein at the saphenofemoral junction (0 cm from SFJ) using 1470 nm radial double-ring diode laser fibers (ELVeS Radial 2ring™ fiber) and Biolitec Ceralas E1470/15 W laser machine. Group B was treated by ablation of the great saphenous vein at 1.5–2 cm from the saphenofemoral junction using the same laser fiber and machine. Ablation was done after putting an appropriate amount of tumescent anesthesia (500 mg lidocaine, 1 mg of epinephrine, and 12.5 mEq sodium bicarbonate added to a 1-liter solution of 0.9% normal saline). The ultrasound machine was used for the accurate placement of the laser fiber. Postoperative duplex was done on day 1, 1 week, and at 6, 12, and 18 months. Results Mean age: 39.28+/– 12.27 years in both groups; M/F: 23/17 in the first group, 20/20 in the second group. Postoperative duplex showed the absence of reflux in both groups after 1 day, after 6 months. One patient (2.5%) in group A and four patients (10%) in group B showed recurrent reflux, while recurrent refluxes were observed in one case (2.5%) in group A and five cases (12.5%) in the other group after 12 and 18 months of follow-up. One patient (2.5%) developed superficial thrombophlebitis along the course of the ablated great saphenous vein in both groups while extension to the deep veins was not detected in both groups. Conclusion Crossectomy (ablation at 0 cm at SFJ) ablation of varicose veins with 1470 radial double rings and nm diode laser with an appropriate amount of tumescent showed better results with less recurrence rate due to neovascularization or tributaries left than the standard technique of endovenous laser ablation of varicose veins (1.5–2 CM from SFJ). Along with showing a lesser incidence of thermal propagation into the deep system (EHIT) both crossectomy and standard techniques showed the same complication rate regarding venous thrombosis.

Comparative study of process parameters on dross properties by laser machining of AISI 316L material

The main aim of this paper is to examine the impact of process parameters on the dross height formation for CO2 and fiber laser machining of SS 316L material. CO2 and fiber laser machining has a small spot size, narrow beam, high intensity, and depth of focus that are conveniently absorbed by the metal surfaces. The work is concentrated on the experimental study of laser machining of SS 316L material for 20 mm thickness. The cut qualities of the workpiece are analysed by measuring the dross height by changing the process parameters like assist gas pressure, laser power, and cutting speed. The experimentation is performed on Bystronic laser cutting machine. In this study, the DOE technique is used implementing the response surface methodology approach. Three factors and two levels are selected, and the total numbers of test runs are 17. Mathematical calculations are carried out using ANOVA. The optimum values of performance parameters are defined to achieve the required minimum dross height. The experimental analysis identified that the CO2 laser process produces higher cut quality as compared to the fiber laser process. The major inference that is drawn from this study is change in cutting speed affects the dross height. Gas pressure did not show much effect on change in dross height formation.

Machining water through laser cutting of nanoparticle-encased water pancakes

Due to the inherent disorder and fluidity of water, precise machining of water through laser cutting are challenging. Herein we report a strategy that realizes the laser cutting machining of water through constructing hydrophobic silica nanoparticle-encased water pancakes with sub-millimeter depth. Through theoretical analysis, numerical simulation, and experimental studies, the developed process of nanoparticle-encased water pancake laser cutting and the parameters that affect cutting accuracy are verified and elucidated. We demonstrate that laser-fabricated water patterns can form diverse self-supporting chips (SSCs) with openness, transparency, breathability, liquid morphology, and liquid flow control properties. Applications of laser-fabricated SSCs to various fields, including chemical synthesis, biochemical sensing, liquid metal manipulation, patterned hydrogel synthesis, and drug screening, are also conceptually demonstrated. This work provides a strategy for precisely machining water using laser cutting, addressing existing laser machining challenges and holding significance for widespread fields involving fluid patterning and flow control in biological, chemical, materials and biomedical research.

Investigations on 355 nm picosecond laser machining of carbon fiber reinforced polymer composites

Carbon fiber reinforced polymer (CFRP) composites have emerged as excellent performance structural materials with a wide range of applications in the aerospace industry. Ultrafast laser is a promising and versatile tool for manufacturing these composites due to its advantages of high peak intensity and ultrashort pulse duration. Herein, a theoretical model based on the Fokker–Planck law and the two-temperature equation, i.e. the ultrafast responses of a two-dimensional heterogeneous material assembly of resin matrix padded with carbon fiber reinforced phase irradiation by 355 nm picosecond laser is established. The evolution of laser-excited free electron density is analyzed, and the relationship between the optical properties of substrate and electron density is revealed. The spatial and temporal distribution of electron and lattice temperatures are thus characterized. The ablation thresholds of resin and carbon fiber are determined, the accuracy of which are verified by experiments. On this basis, orthogonal experiments are conducted to analyze the influence law of process parameters on the ablation depth and heat affected zone (HAZ) width. Optimized parameter groups are discovered to realize the high-quality machining of CFRP composite with considerable depth-to-width ratio and limited HAZ width. This work offers new insight into the fundamental regimes and high-quality machining for picosecond laser manufacturing of CFRP composites.

Laser Machining of Nickel Oxide–Yttria Stabilized Zirconia Composite for Surface Modification in Solid Oxide Fuel Cells

Laser machining of the nickel oxide–yttria-stabilized zirconia (NiO–YSZ) composite in Solid Oxide Fuel Cells (SOFCs) may be an effective approach to enlarge the electrode–electrolyte interface and improve the cell performance. However, laser energy can cause thermal damage to the composite surface during the machined operation. In this work, the microstructure changes and the collateral damage caused by pulsed laser machining on the sintered NiO–YSZ of the state-of-the-art SOFCs were evaluated using complementary analysis techniques. Laser patterns consisting of parallel tracks on sintered NiO–YSZ were processed, varying the laser parameters such as frequency and laser beam energy density. The analyses evidenced a heat-affected zone (HAZ) limited to around 2 µm with microcracking, porosity reduction, and recrystallization. The changes in chemical composition, phase transformation of YSZ and mechanical properties at the machined surface were quite limited.

Generalized thermoelasticity study in ultrashort pulsed laser machining of ceramic considering material removal and variable material properties

Ceramic materials are widely used in engineering due to their excellent properties, but they are difficult to be machined by conventional techniques. Ultrashort pulsed laser is an applicable tool to achieve high-quality processing of these hard-brittle materials. However, the ultrashort thermalization time and complex interactions in laser processing bring great difficulty to describe thermal-mechanical responses precisely. For this purpose, we establish a model for ceramics irradiated by femtosecond pulsed laser in the context of Green-Lindsay generalized thermoelastic theory, considering the effect of material removal and temperature-dependent material properties. Thermoelastic responses and the effect of laser parameters in the machining considering material removal are obtained by means of Finite Element Method. Results show that classical thermoelastic theory underestimates thermal stresses, while G-L thermoelastic theory predicts more accurate responses. Laser parameters, including laser intensity and pulse duration, significantly affect the thermoelastic responses and the process of material removal, which indicates the necessity of laser parameter optimization for reduced thermal stresses and higher processing efficiency. Temperature-dependence of material properties must be considered, as it has pronounced influences on thermoelastic responses. This study can be used as the preparation for the structural safety design in ultrashort pulsed laser machining.

Simulation study and parameter optimization of laser TSV using artificial neural networks

Through-Silicon Vias (TSV) play an important role in the field of semiconductor 3D packaging by providing interconnections during layer-by-layer stacking. Laser machining of TSVs is advantageous over expensive photolithography steps in the DRIE process. It is environmentally friendly, reduces production costs, and increases throughput. In this study, a nanosecond laser (100 ns, 1064 nm) was used to produce TSVs on a 500 μm thick silicon wafer, and the effects on parameters such as drilling depth, aspect ratio, taper angle, and heat-affected zone (HAZ) were investigated in air. Furthermore, an optimized circle-packing design between pulse energy (E) and the number of pulses (N) was constructed. The developed computational model was employed to run simulations to predict the drilling depth, aspect ratio, taper angle, and HAZ. Subsequently, the obtained results were used to train surrogate models for all individual parameters in the given range. A final processing map was created by combining all the individual surrogate models and filtered with four criteria to obtain the optimized region with proper drilling depth, less taper angle, high aspect ratio, and comparatively less HAZ TSVs. Lastly, points were chosen from each region, and experiments were performed to validate the optimized zone, and full agreement was found with the simulation results. With this optimized zone, TSVs with a higher aspect ratio (11.72), less taper angle (1.37°), and comparatively less HAZ thickness (10.48 μm) were achieved for the combination of pulse energy at 0.3614 mJ and pulse number at 835.

Manufacturing Process, Microstructure and Physico-Mechanical Properties of W-Cr Coatings Reinforced by Cr3C2 Phase Produced on Tool Steel through Laser Processing

This paper presents study results of laser processing of W-Cr, WCr/Cr3C2 and Cr3C2 pre-coats applied on steel substrate in the form of paste. For this study, production parameters were selected to obtain the greatest possible durability of final coatings. Laser processing was carried out using a diode laser machine with a rated power of 3 kW. The laser beam scanning speed was constant at 3 m/min, but variable laser beam powers were used: 600 W, 900 W and 1200 W. Multiple laser tracks with 60% overlapping were used. After remelting the pre-coat with a steel substrate, new coatings were obtained. Following the experiment, microstructure, microhardness, wear, corrosion resistance and chemical composition were investigated. It was found that it is possible to produce W-Cr/Cr3C2 coatings through laser processing. These coatings do not have the characteristics of a composite coating; however, increasing the reinforcing phase in the pre-coat positively affects the wear resistance and microhardness. The addition of a reinforcing phase was found to lead to a microhardness of about 750–890 HV01 for 25% and 75% Cr3C2, respectively, in comparison to coating without Cr3C2. The wear resistance of coatings reinforced by chromium carbide improved more than twofold in reference to the W-Cr coating.

Ultra-fast 3D printing of assembly—free complex optics with sub-nanometer surface quality at mesoscale

Complex-shaped optical lenses are of great interest in the areas of laser processing, machine vision, and optical communications. Traditionally, the processing of complex optical lenses is usually achieved by precision machining combined with post-grinding or polishing, which is expensive, labor-intensive and difficult in the processing of ultra-complex optical lenses. Additive manufacturing is an emerging technology that provides significant advantages in producing highly intricate optical devices. However, the layer-by-layer method employed in such manufacturing processes has resulted in low printing speeds, as well as limitations in surface quality. To address these challenges, we apply tomographic volumetric printing (TVP) in this work, which can realize the integrated printing of complex structural models without layering. By coordinating the TVP and the meniscus equilibrium post-curing methods, ultra-fast fabrication of complex-shaped lenses with sub-nanometric roughness has been achieved. A 2.5 mm high, outer diameter 9 mm spherical lens with a roughness value of RMS = 0.3340 nm is printed at a speed of 3.1 × 104 mm3 h−1. As a further demonstration, a complex-shaped fly-eye lens is fabricated without any part assembly. The designed spherical lens is mounted on a smartphone’s camera, and the precise alignments above the circuit board are captured. Upon further optimization, this new technology demonstrates the potential for rapid fabrication of ultra-smooth complex optical devices or systems.

Impact of Green Ceramic Hybrid Machining (GCHM) on Reliability and Repeatability of the Properties of Sintered Yttrium-Tetragonal Zirconia Polycrystal Parts

The innovative Green Ceramic Hybrid Machining (GCHM) process sequentially combines milling with a cutting tool (GCM, Green Ceramic Machining) and laser beam machining (GCLBM) of a ceramic material (black Y-TZP in this study) at the green stage mainly to increase productivity, avoid taper angle limitations of laser beam machining, and obtain micro-features. The study focuses on the reliability and the repeatability of the properties of sintered parts obtained by three manufacturing processes (GCM, GCLBM, GCHM) to assess the performance of hybridisation. It turns out that GCHM is a compromise of both milling and laser beam processes; it increases the repeatability of the surface quality and it slightly reduces (less than 7%) the flexural strength by comparison to milling for a similar reliability. The study also highlights that the surface quality of GCLBM processed parts relies on of the surface generated by the previous operation. Milling that surface at the previous step is therefore recommended, corresponding to the sequence adopted by GCHM.

Effect of laser surface texture on the adhesion performance of CFRP/Mg laminates

ABSTRACT To investigate the enhancement mechanism and effect of laser treatment on the performance of an interface between a carbon-fiber-reinforced polymer and magnesium (CFRP/Mg), finite element simulations and experiments were conducted to demonstrate the macroscopic and microscopic failure processes of the laser-treated interface. Based on the high controllability of the groove parameters in laser machining, the quantitative relationship between the texture parameters and the shear properties of the CFRP/Mg interface was analyzed. In addition, shear tests and simulations of the laser-treated interfaces with different groove parameters were performed. Increasing the groove depth and decreasing the groove spacing effectively improved the shear strength of the CFRP/Mg interface. In addition, the reliability of the interface cohesion parameters obtained using the representative volume element model was verified by experiments and simulations, which is important for the application of laser technology to composite laminates.

Nonlinear free convective with longitudinal slits in the presence of super-hydrophobic and non-hydrophobic microchannels in a suspension of nanoparticles: Multi-Linear Regression Analysis

Super hydrophobic microchannels have extremely high water repellency, and such a property is reliant on a set of factors, namely the surface construction and the surface energy. The surface energy can be depressed either by exhausting a chemical film that is coated or stuck to the surface or by adjusting the existing surface interaction or by producing micro- and nanotextures. Further, due to the latter reason of inducing super hydrophobic properties, a study of manufacturing processes to produce surface textures becomes critical to the understanding of the area. The latest generative manufacturing techniques, such as 3-D (three-dimensional) printing, laser machining, and so on are new-generation processes that can be used to write over surfaces at different resolutions. Viewing into this, the natural convection of conductive nanofluids in vertical slot micro-channels with super-hydrophobic slips and temperature jumps, the non-linear Boussinesq approximation approach provides an accurate solution. One inner surface of the microchannel surface has been physically modified to exhibit temperature jumps and super-hydrophobic velocity slips. The transverse magnetic field indicates the direction of flow. In two different physical situations, it is possible to get a single answer. Type I involves heating the super-hydrophobic surface without heating the non-slip surface, and Type II involves heating the non-slip surface without heating the super-hydrophobic surface. Velocity slip reduces the Type I Nusselt number and increases the Type II Nusselt number in both situations. The temperature jump factor has the opposite effect. In contrast to the change in linear density with temperature, the non-linear density change with temperature causes an increase in flow and velocity. It is observed that more slip coefficient corresponds to less Nusselt number and more slip velocity, especially at larger magnetic parameter values to increase the heat transfer rate from the microchannel walls. It is recommended to use Al2O3-water nanofluid the nanofluid composed of nanoparticles with higher thermal conductivity. Applications of the subject include anti-wetting micro technology, electrolytic cell maintenance, micro-hydraulic devices, and micro-electronic heat dissipation.

High aspect ratio diamond nanosecond laser machining

Laser processing of diamond has become an important technique for fabricating next generation microelectronic and quantum devices. However, the realization of low taper, high aspect ratio structures in diamond remains a challenge. We demonstrate the effects of pulse energy, pulse number and irradiation profile on the achievable aspect ratio with 532 nm nanosecond laser machining. Strong and gentle ablation regimes were observed using percussion hole drilling of type Ib HPHT diamond. Under percussion hole drilling a maximum aspect ratio of 22:1 was achieved with 10,000 pulses. To reach aspect ratios on average 40:1 and up to 66:1, rotary assisted drilling was employed using > 2 M pulse accumulations. We additionally demonstrate methods of obtaining 0.1° taper angles via ramped pulse energy machining in 10:1 aspect ratio tubes. Finally, effects of laser induced damage are studied using confocal Raman spectroscopy with observation of up to 36% increase in tensile strain following strong laser irradiation. However, we report that upon application of 600 °C heat treatment, induced strain is reduced by up to ~ 50% with considerable homogenization of observed strain.

Analytical study for the selection of mask size and shape for obtaining high machining quality of complex features

In this article, an analytical study of the effect of the shape and size of the mask on the machining quality of complex shapes has been carried out. For this study, we considered square and circular masks of varying sizes with varying overlap for the machining of square, inclined, and circular features. Mask size varied from 1 to 20 mm, while overlap varied from 10% to 90%. The machining quality of the aforementioned features was evaluated by studying the unmachined area “An” (in the machining zone) and the machining time “Tm.” For machining a similar feature, it was observed that the square mask performed much better than the circular mask in minimizing the machining time. However, the circular mask is much more suitable for minimizing the unmachined area. For validation, the experiment was conducted to machine the inclined lines with square and circular shape masks with varying overlap percentages. The experimental results were found to be in good agreement with the analytically obtained results, with an error of 2.5%. This study is relevant for the industrial-scale manufacturing of complicated features using the mask projection approach in laser machining.