This study investigates the hole formation mechanisms in double-sided laser drilling of Ti6Al4V-C/SiC stacked materials. The research aims to address the limitations of conventional single-sided laser drilling by exploring the potential of double-sided laser drilling (DSLD) for producing high-quality holes in this challenging material combination. The study combines computational fluid dynamics (CFD) modeling with experimental investigations to understand the melt pool dynamics, recast layer formation, and microstructural changes during the drilling process. A hybrid CFD model integrating the volume of fluid (VOF) method and level set method was developed to simulate the evolution of hole shape, recast layer formation, and melt pool flow behavior. The model provides insights into the molten pool dynamics under various drilling conditions, helping to understand the mechanisms driving recast layer formation and influencing surface quality. Experimental investigations were conducted under various drilling conditions, with samples analyzed using advanced materials characterization techniques such as scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and electron backscatter diffraction (EBSD) to elucidate microstructural evolution within the recast layer and the formation of the heat-affected zone (HAZ). The results show that DSLD produces better hole morphology, surface roughness, and reduced recast layer formation compared to single-sided laser drilling (SSLD). The study also highlights the complex material interactions at the interface between Ti6Al4V and C/SiC, which significantly affect the drilling process. The CFD model was validated against experimental results, demonstrating its effectiveness in simulating the hole formation process. Microstructural analysis revealed that the recast layer in Ti6Al4V contains irregularities and cracks due to thermal stresses, while the HAZ primarily consists of lath martensite. The phase maps showed the presence of both α and β phases in the recast layer, with the β phase increasing due to the high temperature of the recast layer exceeding the β phase transition temperature. The grain sizes in the recast layer and HAZ were significantly reduced compared to untreated Ti6Al4V, indicating grain refinement due to rapid cooling during laser drilling. The study also found that DSLD results in a lower recast layer formation and better surface quality compared to SSLD. The results suggest that DSLD is a promising technique for drilling Ti6Al4V-C/SiC stacked materials, although the technology is currently limited to laboratory scales and lacks capacity for manufacturing complex parts. Future research should focus on improving the technology to enable real-world applications.This study investigates the hole formation mechanisms in double-sided laser drilling of Ti6Al4V-C/SiC stacked materials. The research aims to address the limitations of conventional single-sided laser drilling by exploring the potential of double-sided laser drilling (DSLD) for producing high-quality holes in this challenging material combination. The study combines computational fluid dynamics (CFD) modeling with experimental investigations to understand the melt pool dynamics, recast layer formation, and microstructural changes during the drilling process. A hybrid CFD model integrating the volume of fluid (VOF) method and level set method was developed to simulate the evolution of hole shape, recast layer formation, and melt pool flow behavior. The model provides insights into the molten pool dynamics under various drilling conditions, helping to understand the mechanisms driving recast layer formation and influencing surface quality. Experimental investigations were conducted under various drilling conditions, with samples analyzed using advanced materials characterization techniques such as scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and electron backscatter diffraction (EBSD) to elucidate microstructural evolution within the recast layer and the formation of the heat-affected zone (HAZ). The results show that DSLD produces better hole morphology, surface roughness, and reduced recast layer formation compared to single-sided laser drilling (SSLD). The study also highlights the complex material interactions at the interface between Ti6Al4V and C/SiC, which significantly affect the drilling process. The CFD model was validated against experimental results, demonstrating its effectiveness in simulating the hole formation process. Microstructural analysis revealed that the recast layer in Ti6Al4V contains irregularities and cracks due to thermal stresses, while the HAZ primarily consists of lath martensite. The phase maps showed the presence of both α and β phases in the recast layer, with the β phase increasing due to the high temperature of the recast layer exceeding the β phase transition temperature. The grain sizes in the recast layer and HAZ were significantly reduced compared to untreated Ti6Al4V, indicating grain refinement due to rapid cooling during laser drilling. The study also found that DSLD results in a lower recast layer formation and better surface quality compared to SSLD. The results suggest that DSLD is a promising technique for drilling Ti6Al4V-C/SiC stacked materials, although the technology is currently limited to laboratory scales and lacks capacity for manufacturing complex parts. Future research should focus on improving the technology to enable real-world applications.