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Use cases/Use case/Semiconductor processing
Use case · 3D Top-Hat

Stable processing over a millimetre-scale focus range.

A very small flat-top that stays on-size and uniform across a 4–6 mm focus range, so laser processing of semiconductor materials no longer hinges on a knife-edge focus. Measured with an industry partner.

Product: 3D Top-Hat Application: Micro-machining Industry: Semiconductor Partner: Industry partner
Challenge
  • Tight focus tolerances: the process sits on a narrow band of Z-positions
  • Limited depth of field with conventional shapers
  • High process sensitivity to defocus, part height and thermal drift
Result
  • Stable flat-top across a 4–6 mm focus range (≈50–75% of the usable depth of focus)
  • Wider, more forgiving process window: Z9 through Z12 all pass
  • Drop-in with minimal adjustment; robust processing for semiconductor applications
A wider process window turns a fragile, focus-critical laser process into a tolerant, production-ready one.
Setup & conditions: laser processing of semiconductor materials with an industry partner; measured stable across a 4–6 mm focus range (≈50–75% DOF), vs. ~2 mm for a conventional top-hat.
Processed dot array across Z7–Z14: Z9–Z12 (green) stay in spec, with beam-profile insets at each planeA laser-processed dot array on a semiconductor sample, shown across focus positions Z7 to Z14; positions Z9 to Z12 are highlighted green as in-spec, each with a measured flat-top beam-profile inset above it
Midel 3D Top-Hat vs. conventional

Reduced setup complexity in production

3D Top-Hat

Drop-in with minimal adjustment. A 4–6 mm process window means the same recipe holds across part-height variation and refocus.

Conventional top-hat

Complex tuning required, and only a ~2 mm process window. Every job needs an exact refocus and yield swings with defocus.

What you get

Reduced setup complexity, higher yield and repeatable processing across shifts and machines: a robust basis for volume production.

Comparison from measurements with the industry partner. Values are configuration-specific and confirmed per setup.

Related

Product & further use cases

3D Top-Hat

Depth-of-field-engineered homogenized flat-top.

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Precision micro-machining

Flatter floors & cleaner walls than a Gaussian.

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Engraving on a tilted surface

>3× larger process window, >2× better finish.

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