Process Repeatability in Jig-Assisted UV Nanosecond Laser Ablation of Micro-Wires

This study investigates the process control and improvement in the repeatability of UV nanosecond laser ablation of polyamide-coated platinum micro-wires while preserving post-ablation mechanical integrity. For this purpose, a jig was developed to control wire positioning, alignment, focal distance, rotation, and immersion depth during water-assisted laser processing. Selected ablation conditions were repeated and compared with corresponding results from previous work, while additional uncoiled and unablated specimens were included to examine the influence of prior wire condition and provide a mechanical reference. Surface quality was evaluated using microimaging and surface roughness measurements, and mechanical response was assessed through pull-to-rupture testing. The surface results showed that the selected processing conditions produced different levels of roughness and surface uniformity, while the mechanical results showed improved consistency in the jig-assisted trials compared with the previous datasets. The comparison also indicated that prior wire handling and mechanical history can influence rupture behavior independently of the laser process. Overall, the results support the use of controlled mechanical referencing as an effective approach for improving repeatability in water-assisted laser coating removal.