The forming of a micro tapered hole is based on nanosecond pulsed laser processing, which conforms to fast processing time and high throughput; however, the microhole quality should be improved. Micro stamping is a technology providing high precise size and speed. The greatest difficulty in forming a microhole by micro stamping is the precision alignment of the punch head to the lower die. In order to overcome the difficulty, we proposed a concept of stamping without die (SWD). Without a lower die, the tapered punch head was directly applied to the workpiece for micro stamping, and a thicker workpiece surrounding the punching area provides a better support to the stamping process. Thus, a successful forming of micro tapered holes is completed. The micro tapered hole depth is 300 μm, and the maximum ratio of inlet to outlet diameter is 18:1. In order to reduce the number of experiments, the finite element analysis software DEFORM-3D was used for forming analysis. The simulation forecast result was compared with the experimental processing, which was well validated. Under different experimental parameters of laser energy and defocusing distance, drilling results by two methods show that the microhole quality by stamping process is better than by laser processing.

Aluminum alloy (Al6061) sheet micro-hole processing is extensively used in smartphones, tablet PC, and smart wearable devices. The micro-hole processing is commonly performed using laser, micro drilling, microstamping, micro discharge, and chemical etching technologies. Micro-stamping technology is characterized by precision and rapid processing, but the precision positioning of the punch head and lower die is one of the major difficulties in micro-hole stamping, especially in manufacturing array micro-holes. This study used stamping without die technology. This technology uses an array punch head to punch the lower die holes on the base, then performs array micro-hole stamping. The experimental results show that a micro-hole array with 37 micro-holes were successfully manufactured and can be reproduced many times. Tapered array micro-holes with a high aspect ratio can be manufactured using this stamping without die technology; the micro-hole depth can be 260μm, the inlet diameter is 116μm, and the outlet diameter is 25μm. This study has successfully developed the feasibility of array micro-hole stamping technology.