Precision manufacturing of pinholes and slits

   In Danish

Get micrometer-precise pinholes and slits for optics, diagnostics, and leak testing - manufactured using FIB-SEM and advanced laser technology.

Pinholes and slits with micrometer precision are critical components in optical detection systems, diagnostic instruments, and leak testing. Danish Technological Institute manufactures pinholes and slits with dimensional accuracy down to 1 µm across a wide range of materials - from thin metal films to polymers, ceramics, and glass.

When micrometer-scale precision is critical for your product

In many advanced products and instruments, functionality depends on light, gas, or liquid passing through an aperture with precisely controlled size and shape. Deviations of just a few micrometers can lead to unreliable measurement results, miscalibration, or scrapped products.

The challenge is that conventional drilling and punching methods rarely achieve the required precision on a micrometer scale - particularly in thin films and fragile materials such as polymers, ceramics, and glass. Mechanical machining risks deforming the material, creating ragged edges, or damaging the surrounding material, compromising the pinhole’s function.

Typical situations where standard methods fall short:

• Hole diameters below 50 µm, where mechanical drilling cannot achieve sufficient dimensional accuracy
• Thin materials below 500 µm that deform or crack under mechanical processing
• Demanding material combinations such as ceramics, glass, rubber, or thin metal films, where conventional machining creates unacceptable edge defects
• Applications with tight tolerances, such as calibrated reference leaks for leak testing or apertures for optical systems where edge definition and circularity are critical
• Non-circular geometries such as slits or square holes that require precise shape control on a micrometer scale

When product performance, measurement accuracy, or certification depends on pinhole quality, specialized manufacturing methods like FIB-SEM and laser machining are required - technologies that few companies have in-house.

How can Danish Technological Institute help you?

We manufacture precise pinholes and slits for demanding applications. Our equipment and expertise cover: 

• Pinholes from 2 to 500 µm in diameter - tailored to your specific application
• FIB-SEM processing of pinholes and slits in thin metal films and polymers with accuracy down to 1 µm
• Laser machining using femtosecond lasers and excimer lasers for larger hole sizes and thicker materials
• Circular and non-circular shapes, including square holes and slits
• Machining across a broad spectrum of materials: steel, titanium, PET, Kapton, Teflon, PEEK, ceramics, glass, and rubber
• Well-defined patterns and structures in materials thinner than one millimeter
• Optimization of the machining process for your specific product and requirements

When are precision-manufactured pinholes relevant?

Pinholes with controlled diameter and edge definition are essential in applications where light, gas, or liquid must pass through a precisely defined opening. Typical applications include: 

• Optical detection systems where hole diameter controls light throughput and resolution
• Diagnostic instruments within medical devices and analytical chemistry
• Leak testing where calibrated pinholes serve as reference leaks
• Sensor and detector technology where precise apertures are critical for measurement accuracy

Danish Technological Institute is an independent, self-governing Research and Technology Organisation (RTO) equipped with specialized facilities for micro- and nanoscale processing. This gives you direct access to technologies such as FIB-SEM and specialized lasers without requiring capital investment in the equipment yourself.

Specifications and capabilities

With our focused ion beam scanning electron microscope (FIB-SEM), we can produce pinholes and slits ranging from 2–50 microns in diameter. Our process supports both circular and non-circular shapes, including square holes and slits. These features can be created in thin films of metal (such as steel or titanium) or polymers (such as PET and polyimide), with film thicknesses of up to 20 microns.

FIB-SEM is particularly suited for applications requiring micron-level accuracy in thin materials

FIB-SEM manufacturing of pinholes and slits

Our manufacturing process ensures that each pinhole meets the highest standards - with a dimensional accuracy of down to ± 1 µm

Read more

For larger pinholes or thicker materials (up to 500 microns), our laser laboratory offers additional capabilities. Using specialized laser equipment, we can machine precise holes and patterns in a wide variety of materials, including polymers, ceramics, glass, and rubber. Our lab is equipped with an excimer lasers.

This technology allow us to create well-defined holes and patterns with diameters ranging from 5 to 500 micrometers. Materials processed include polymers (e.g., PET, Teflon, Kapton), ceramics, steel, and glass.

Laser micromachining

We specialize in laser structuring of products thinner than a millimeter. The laser cutting process is optimized to your product and your needs, and we are experts in cutting well-defined holes with a diameter of between 5-500 micrometers. 
Read more

Laser cutting in plastic materials

Our specialty in laser structuring is plastic products thinner than a millimeter. The laser cutting process is optimized to your product and your needs, and we specialize in cutting well-defined holes with a diameter of between 5-500 micrometers. 
Read more

Summary of Capabilities

Let us manufacture precision pinholes for your application

Contact Danish Technological Institute to discuss your specific needs for pinholes, slits, or microstructuring. We will help you select the right technology and optimize the process for your material and requirements.