A micro melting process to melt surface irregularities or features on a surface of a substrate. The method includes providing a laser and a control mechanism associated with the laser. The control mechanism is used to melt the surface irregularities on the substrate. The control mechanism varies the laser intensity and direction by varying and monitoring the power of the laser. The approach direction of the laser is used to control the manner in which irregularities or surface features are melted, ambient atmospheric conditions, induced motion between the laser and the surface being processed.