This study investigates the advanced application of laser micro-perforation technology in the manufacturing of sandwich-structured materials for airbag deployment zones, with a focus on optimizing laser processing parameters to ensure precise perforation while maintaining structural integrity. Given the critical safety role of airbag systems, the consistency and accuracy of micro-perforations are essential for predictable rupture behaviour under impact conditions. Laser micro-perforation is widely adopted in the automotive industry due to its ability to create high-precision perforations with minimal material degradation, facilitating controlled airbag deployment. Optimizing key laser parameters—pulse energy, repetition rate, focal positioning, scanning speed, and pulse overlap—enhances perforation uniformity while minimizing heat-affected zones (HAZ) and residual stresses that could compromise performance. A dual-validation methodology ensures the reliability of perforated materials. The first validation assesses mechanical strength, requiring a minimum rupture force of 2000 N to maintain durability under normal conditions while allowing controlled fracturing during airbag activation. The second validation involves microscopic analysis of perforations, focusing on geometric precision, spacing uniformity, and edge definition. High-resolution imaging techniques, such as scanning electron microscopy (SEM) and optical profilometry, confirm adherence to automotive safety standards and minimize defects caused by thermal distortion. Integrating adaptive laser control and real-time monitoring enhances process repeatability, reduces production variability, and improves manufacturing efficiency. This study underscores the importance of fine-tuning laser parameters and rigorous validation in optimizing airbag deployment reliability, ensuring compliance with stringent safety regulations while advancing precision laser processing in the automotive industry.