Method and apparatus to form dimensionally consistent orifices and chamfers by laser using spatial filters

A method of forming at least one chamfer and at least one orifice in a workpiece, the at least one orifice having an axis extending between a first surface and second surface of the workpiece, the at least one chamfer being disposed between the first surfaces and the second surfaces, the method comprising:

• transmitting laser light in at least one predetermined mode;
• separating at least one of amplified spontaneous emission of light and non-collimated light from the at least one laser light source;
• forming at least one orifice in a workpiece with the laser light in the at least one predetermined mode during a first time interval;
• and
• forming at least one chamfer with at least one of the amplified spontaneous emission and non-collimated lights at a second time interval during the first time interval.

A laser system to machine at least one orifice and at least one chamfer in a workpiece, the laser system comprising:

• at least one laser light source;
• at least one optical arrangement that directs collimated light towards the workpiece during a first time interval and non-collimated light towards the work piece during a second time interval that overlaps the first time interval, the optical arrangement including:
• focusing optic disposed between the at least one laser light source and the workpiece;
• at least one spatial filter disposed between the focusing optic and the work piece;
• and
• at least one shutter and iris arrangement disposed between the spatial filter and the work piece.