As consumer electronics evolve toward thinner, lighter, and more flexible designs, new materials are reshaping the manufacturing process. One standout example is ultra-thin glass (UTG)—a highly flexible, transparent material that can be as thin as 30μm. UTG offers a unique combination of durability and bendability, making it a critical component in next-generation devices like foldable smartphones, wearables, and flexible sensors. But its exceptional thinness also presents a major challenge: it’s extremely fragile and prone to cracking during processing.
So how can manufacturers cut such delicate material with high precision, without damaging it? The answer lies in advanced non-contact laser cutting technology.
The Challenge of Cutting Ultra-Thin Glass
At just 30μm thick, UTG is more like a film than a traditional glass sheet. It behaves differently under stress, offering limited tolerance to mechanical forces and thermal expansion. Conventional cutting methods—such as mechanical scoring or scribing—often cause microcracks or edge chipping, which can compromise the strength, optical quality, and long-term reliability of the final product.
The Laser Cutting Advantage
Laser cutting offers a contact-free solution that eliminates the mechanical stress associated with traditional methods. However, cutting ultra-thin glass demands more than just a standard laser cutting machine. The process must be highly controlled, with a focus on low energy density and high repetition frequency to ensure clean, precise edges without introducing heat-related damage.
Key Process Parameters
Non-Contact Cutting
The laser beam interacts with the glass surface without physical contact, reducing the risk of breakage or edge defects.
Low Energy Density
Lowering the energy per pulse minimizes thermal shock and prevents the glass from cracking due to localized heating.
High Repetition Frequency
Fast pulse rates ensure smoother cuts and finer edge quality, distributing energy more evenly along the cutting path.
This combination of parameters allows manufacturers to achieve smooth, micro-crack-free edges, even on flexible substrates as thin as 30μm.
Applications Driving Demand
Flexible UTG is at the forefront of some of today’s most exciting technology trends. Precision laser cutting plays a vital role in enabling these innovations:
Foldable Smartphones
UTG forms the outer layer of foldable displays. Clean, accurate laser cuts are essential for edge quality, sealing, and structural integrity.
Wearable Devices
Smartwatches and fitness bands require small, curved, and lightweight components. Laser cutting ensures reliable production of intricate shapes without damaging the material.
Flexible Sensors
In medical and industrial applications, sensors made with ultra-thin glass need to be both accurate and unobtrusive. Laser cutting provides the accuracy needed to produce consistent sensor substrates at micro-scale.
Conclusion
Ultra-thin glass offers unmatched flexibility and optical clarity, but its extreme fragility demands a cutting solution that is both precise and gentle. Non-contact laser cutting—with carefully tuned low energy and high-frequency parameters—has become the go-to approach for processing UTG in advanced applications.
As the demand for foldable and wearable devices grows, manufacturers need cutting technologies that can keep up with both the material and the market. Han’s Laser provides cutting-edge laser solutions tailored for ultra-thin and flexible materials—ensuring high quality, high yield, and high performance.
Contact Han’s Laser today to learn how our laser cutting systems can help you unlock the full potential of flexible glass in your next innovation.