Rethinking laser micromachining for smarter manufacturing
As industrial requirements evolve, manufacturing processes must deliver greater precision, flexibility and efficiency. This is precisely the ambition behind METAMORPHA, a European collaborative project bringing together industrial partners, research centres and technology experts to advance laser micromachining through smarter, more adaptive and more sustainable processes.
At the core of the project lies a strong conviction: the future of industrial photonics depends on combining programmable beam shaping, in-line process control and intelligent process management.
Within this framework, LASEA contributes to the development of a platform based on an LS5 machine equipped with a 120W laser and a dual-SLM optical module (Spatial Light Modulators), designed to explore new micromachining approaches for complex metallic parts. METAMORPHA fully reflects LASEA’s vision: turning advanced photonics research into concrete industrial processes.
The principle behind the project: made-to-measure micromachining
Made-to-measure micromachining with laser beams tailored in amplitude and phase explores a new generation of laser processes in which the beam itself becomes programmable.
The project relies on several complementary technological building blocks:
Advanced digital beam shaping
Using a dual-SLM configuration, the system can control both beam amplitude and phase to generate laser profiles tailored to each manufacturing operation.
Processes adapted to each component
3D topography sensing and optimisation algorithms make it possible to adapt the process to geometry and material variations, with the objective of first-time-right production.
In-line control and agile manufacturing
The project also integrates real-time monitoring and a modular process architecture designed to scale from development to production.
The ambition is clear: reduce process chains, improve material and energy efficiency, and unlock new possibilities for high-precision micromachining.
Three industrial use cases validating the technology
METAMORPHA is developed with three industrial end-users representing different manufacturing challenges:
- micromachining of complex metallic parts
- processing of large-scale embossing rolls
- machining of punches and hard-material components
These use cases help validate the versatility of the technology across different geometries, materials and industrial constraints.
Research & development: when photonics becomes adaptive
Beyond machine development, METAMORPHA illustrates a deeper evolution in photonic manufacturing.
It is no longer only about increasing precision, but about making the process itself adaptive.
This opens perspectives in several areas:
- dynamically controlled ultrafast micromachining
- advanced surface structuring
- intelligent process optimisation
- more sustainable manufacturing through fewer process steps and reduced energy consumption
This dynamic naturally aligns with LASEA’s R&D activities and the approach developed through the LASEA LAB, where new processes are explored together with industrial and academic partners.
FAQ — Understanding the METAMORPHA Project
METAMORPHA is a Horizon Europe project focused on advanced laser micromachining processes based on digital beam shaping, intelligent process control and modular manufacturing architectures.
Its goal is to develop a new generation of laser processes that are more flexible, efficient and sustainable, capable of replacing or simplifying conventional manufacturing routes.
LASEA contributes to the development and demonstration of the micromachining platform, as well as to the exploration of the associated new laser processes.
It enables dynamic shaping of the laser beam and allows the process to be tailored to the exact needs of each application.
The project connects closely with several LASEA laser processes, including:
- Cutting
- Drilling
- Texturing
- Functional laser engraving
- Advanced beam shaping processes
About LASEA
LASEA is an international specialist in high-precision laser micromachining. The company designs and manufactures laser systems for industries that require extreme levels of precision, reliability and flexibility.
Its technologies are used in sectors such as MedTech, microelectronics, watchmaking, aerospace and advanced research, where mastering manufacturing processes is critical.
By combining ultrafast lasers, modular architectures and proprietary software, LASEA supports its customers at every stage of their projects, from research and development to industrial production.
The METAMORPHA project has received funding from Horizon Europe, the European Union’s Framework Programme for Research and Innovation, under grant agreement 101057457.
Views and opinions expressed are however those of the authors only and do not necessarily reflect those of the European Union. The European Union cannot be held responsible for them.
