We considered possibilities of an application of diffractive free-form optics in laser processing of metallic materials in aerospace production. Based on the solution of the inverse problem of heat conduction, an algorithm was developed that calculates the spatial distribution of the power density of laser irradiation in order to create the required thermal effect in materials. It was found that the use of diffractive optics for the laser beam shaping made it possible to obtain specified properties of processed materials. Laser thermal hardening of parts made of chrome–nickel–molybdenum steel was performed. This allowed us to increase the wear resistance due to the creation in the surface layer of a structure that has an increased hardness. In addition, a method of laser annealing of sheet materials from aluminum–magnesium alloy and low-alloy titanium alloys was developed. Application of this method has opened opportunities for expanding the forming options of these materials and for improving the precision in the manufacturing of aircraft engine parts. It was also shown that welding by a pulsed laser beam with a redistribution of power and energy density makes it possible to increase the strength of the welded joint of a heat-resistant nickel-based superalloy. Increasing the adhesion strength of gas turbine engine parts became possible by laser treatment using diffractive free-form optics.

This article explores the integration of artificial intelligence (AI) and advanced digital technologies into laser processing, highlighting their potential to enhance precision, efficiency, and process control. The study examines the application of digital twins and machine learning (ML) for optimizing laser machining, reducing defects, and improving the analysis of laser–material interactions. Emphasis is placed on AI’s role in additive manufacturing and microprocessing, particularly in real-time monitoring, defect prediction, and parameter optimization. Additionally, the article addresses emerging challenges, such as the adaptation of AI models to complex material behaviors and the integration of intelligent systems into existing manufacturing environments. The role of advanced optical technologies, such as free-form optics and diffractive optical elements, is discussed in relation to enhancing laser system adaptability and performance. The article concludes with a discussion on future trends, emphasizing the need for interdisciplinary collaboration to overcome technical and economic complexities while leveraging AI to meet the growing demand for precision and customization in industrial manufacturing.

Laser processing is a versatile tool that enhances smart materials for diverse industries, allowing precise changes in material properties and customization of surface characteristics. It drives the development of smart materials with adaptive properties through laser modification, utilizing photothermal reactions and functional additives for meticulous control. These laser-processed smart materials form the foundation of 4D printing that enables dynamic shape changes depending on external influences, with significant potential in the aerospace, robotics, health care, electronics, and automotive sectors, thus fostering innovation. Laser processing also advances photonics and optoelectronics, facilitating precise control over optical properties and promoting responsive device development for various applications. The application of computer-generated diffractive optical elements (DOEs) enhances laser precision, allowing for predetermined temperature distribution and showcasing substantial promise in enhancing smart material properties. This comprehensive overview explores the applications of laser technology and nanotechnology involving DOEs, underscoring their transformative potential in the realms of photonics and optoelectronics. The growing potential for further research and practical applications in this field suggests promising prospects in the near future.

A method of composite nanomaterials synthesis under metal/oxide pulse-periodic laser treatment has been developed on the example of a metal-semiconductor nanocomposite ZnO/Cu. A new approach to the creation of structures of layered composite nanomaterials based on zinc oxide nanofibers is implemented. For the first time for such materials synthesis, heating laser controlled distribution of power density has been used. Air heating of foil brass by pulse-periodic laser treatment intensifies the oxidation of the surface material. Preferable formation of ZnO is caused by a higher oxidation speed of zinc than copper and the zinc diffusion to the surface, as well. The length of zinc oxide nanofibers in the implementation of the selected modes of the laser treatment is less than 5 micrometers.