This study investigates the hole formation mechanisms in double-sided laser drilling (DSLD) of Ti6Al4V-C/SiC stacked materials, a challenging material combination for high-temperature structural applications. The research combines computational fluid dynamics (CFD) modeling with advanced microstructure analysis to understand the melt pool formation process and its impact on hole morphology and quality. A hybrid CFD model integrating the volume of fluid (VOF) and level set methods is developed to simulate hole shape evolution, recast layer formation, and melt pool flow behavior. Experimental investigations are conducted across various laser drilling conditions, and samples are analyzed using scanning electron microscopy, energy dispersive spectroscopy, and electron backscatter diffraction to elucidate microstructural evolution and heat-affected zone (HAZ) formation. The results show that DSLD outperforms single-sided laser drilling (SSLD) in terms of hole morphology, surface roughness, and reduced recast layer formation. The study also highlights the complex interactions between Ti6Al4V and C/SiC during laser drilling, particularly the formation of recast layers and HAZ. The numerical model, named CLSVOF, effectively captures the evolution of hole formation, recast layer, and melt pool flow behaviors. The experimental findings align well with the modeling results, providing a comprehensive understanding of the DSLD mechanisms in Ti6Al4V-C/SiC materials. Despite the promising results, the technology is currently limited to laboratory scales and requires further development for real-world applications.This study investigates the hole formation mechanisms in double-sided laser drilling (DSLD) of Ti6Al4V-C/SiC stacked materials, a challenging material combination for high-temperature structural applications. The research combines computational fluid dynamics (CFD) modeling with advanced microstructure analysis to understand the melt pool formation process and its impact on hole morphology and quality. A hybrid CFD model integrating the volume of fluid (VOF) and level set methods is developed to simulate hole shape evolution, recast layer formation, and melt pool flow behavior. Experimental investigations are conducted across various laser drilling conditions, and samples are analyzed using scanning electron microscopy, energy dispersive spectroscopy, and electron backscatter diffraction to elucidate microstructural evolution and heat-affected zone (HAZ) formation. The results show that DSLD outperforms single-sided laser drilling (SSLD) in terms of hole morphology, surface roughness, and reduced recast layer formation. The study also highlights the complex interactions between Ti6Al4V and C/SiC during laser drilling, particularly the formation of recast layers and HAZ. The numerical model, named CLSVOF, effectively captures the evolution of hole formation, recast layer, and melt pool flow behaviors. The experimental findings align well with the modeling results, providing a comprehensive understanding of the DSLD mechanisms in Ti6Al4V-C/SiC materials. Despite the promising results, the technology is currently limited to laboratory scales and requires further development for real-world applications.