Hard and brittle materials possess excellent mechanical, optical, and chemical properties. However, the demand for efficient and high-precision processing drives continuous innovation in modern processing technologies. Laser processing plays an increasingly important role in high-precision cutting and shaping of these materials due to its high flexibility, precision, and non-contact nature. In this study, we overview the current research and progress on the key technologies of laser high-precision cutting and shaping of hard and brittle materials, particularly focusing on applications involving large thickness/large length ratio, multi-dimensional components, and composite cutting and forming. In addition, we discuss the challenges and prospects of this technology, aiming to provide theoretical guidance and a technical foundation for the advancement of related industries.

We first discuss the fundamental interaction between lasers and brittle materials. We elaborate on the laser processing of large thickness brittle materials, high-precision cutting of multi-dimensional components, and composite cutting and forming technologies. Besides, we analyze the technical principles, advantages, and application examples of these technologies, which lays a solid foundation for innovations in laser cutting of hard and brittle materials. For the laser cutting of materials with large thickness or a high length-to-diameter ratio, methods such as non-destructive close piercing, multi-focal distribution spherical aberration correction, Bessel beam modulation, and laser filamentation have been successfully applied to address issues like heat accumulation, beam aberration, and energy loss. These methods enable high-precision cutting of thick, hard, and brittle materials, including the machining of complex structures that are challenging for traditional methods. In multi-dimensional structure cutting, the application of computer numerical control (CNC) technology enables precise multi-dimensional laser cutting and structuring. The closed-loop feedback system, with high-precision positioning and trajectory control, plays a crucial role in achieving accurate multi-dimensional cutting and forming. Laser composite cutting and forming technologies significantly improve cutting accuracy and quality by integrating laser techniques with other processing methods. Coupling laser processing with mechanical methods, liquid assistance, chemical etching, and optical far-field-induced near-field breakdown (O-FIB) effectively reduces thermal damage, microcracks, and recast layers. These composite methods not only increase processing efficiency but also expand the range of applications for hard and brittle materials, enabling more intricate multi-dimensional structures. The progress of laser high-precision cutting methods enhances the machining accuracy and efficiency of hard and brittle materials, broadening their application prospects in fields such as precision instruments, artificial intelligence, and bioengineering. With continuous advancements, laser cutting and shaping technologies will play a more significant role in future micro/nano-manufacturing.

Laser cutting technology is widely used in industrial manufacturing due to its ability to enhance machining accuracy and efficiency while minimizing thermal effects. We systematically review recent advances in laser high-precision cutting and shaping of hard and brittle materials. By integrating cutting-edge techniques such as chemical etching, multiphoton absorption, and liquid-assisted methods, laser cutting effectively mitigates issues like thermal stress and microcracking. Particularly for complex structures and large-thickness materials, innovative approaches such as Bessel beams, multi-focus technology, and far-field-induced near-field enhancement further improve cutting performance and precision. As new materials, including composites and functional materials, emerge, laser cutting technology continues to expand in its applications. Further exploration of the interaction between lasers and various materials, as well as optimization of processes tailored to new material requirements, is necessary. The deep integration of laser technology with intelligent manufacturing and automation will provide a powerful momentum for the future development of high-end equipment.