A critical review on laser-assisted paint removal from carbon fibre-reinforced polymer: Insights into process parameters, material integrity, and numerical modelling

Laser-based paint stripping has emerged as a precise, efficient, and environmentally sustainable technique for removing paints/coatings from carbon fibre-reinforced polymer (CFRP) composites. This review presents a comprehensive analysis of laser-material interaction mechanisms that govern paint removal, including thermal ablation, thermally induced interfacial failure, plasma shock wave generation, and photochemical bond disruption. The influences of thermal and optical properties of CFRP and paint on interaction dynamics and removal behaviours are critically examined. The key laser processing parameters are systematically analysed in relation to stripping efficiency, substrate preservation, and thermal loading. Experimental methods used for monitoring process response and evaluating removal quality are also reviewed. Numerical modelling approaches based on the finite element method are discussed, with a focus on simulating transient heat transfer, interfacial stresses, and coupled effects. Limitations of current models in capturing the complexity of pulsed laser interaction with multilayered paint-composite structure are addressed. The review highlights that while laser stripping offers selective, damage-free paint removal, challenges remain in managing thermal effects, ensuring layer-specific selectivity, and achieving process scalability. Addressing these challenges is essential for translating laser-based stripping into reliable maintenance solutions for aerospace, defence, renewable energy, and automotive industries.