| Criteria | Spark Erosion (EDM) | Laser Ablation |
|---|---|---|
| Principle | Uses electrical discharge to erode material. | Uses focused laser light to remove material. |
| Process | Material is removed by electrical sparks between an electrode and the workpiece. | Material is ablated by high-energy laser pulses. |
| Material Types | Effective for conductive materials (e.g., metals). | Suitable for both conductive and non-conductive materials (e.g., metals, polymers). |
| Precision | High precision with tolerance in micrometers. | High precision with sub-micrometer resolution. |
| Surface Finish | Generally achieves a rough surface finish but can be improved with post-processing. | Can achieve smooth surface finishes, often with minimal post-processing. |
| Heat Affected Zone (HAZ) | Minimal heat-affected zone due to localized erosion. | Low heat-affected zone as the material is removed in a localized area. |
| Tool Wear | Electrode wear occurs and needs replacement. | No tool wear as the laser is non-contact. |
| Material Removal Rate | Generally slower removal rate compared to laser. | Faster material removal rate, especially in thin sections. |
| Cost | Initial setup cost is moderate; electrode replacement adds to cost. | High initial cost for laser systems, but no consumables needed. |
| Complexity of Setup | Requires careful setup and alignment of electrodes. | Setup complexity involves aligning and focusing the laser. |
| Energy Consumption | Relatively low energy consumption per discharge. | Higher energy consumption due to high-power lasers. |
| Environmental Impact | Generates sparks and can produce fumes. | Produces minimal fumes, but requires careful management of laser safety. |
| Applications | Common in tooling, mold making, and intricate part fabrication. | Widely used in micro-machining, engraving, and precision cutting. |
| Safety Considerations | Electrical hazards and potential exposure to high temperatures. | Laser safety is paramount, including eye protection and handling precautions. |
| Efficiency | Efficient for certain geometries and materials, but slower overall. | Generally more efficient for a wide range of applications. |
| Flexibility | Limited to specific shapes and conductive materials. | High flexibility in terms of material types and shapes. |
High precision and flexibility make laser ablation the preferred choice for a broader range of applications, although spark erosion remains valuable for specific conductive material applications and intricate part fabrication.