Abstract: A fuel injector housing having a main body portion and a tip portion is disclosed. The main body portion has a chamber defined therein in which fuel injector components may be positioned. The tip portion has a nozzle defined therein. The nozzle has a passageway extending therethrough which is in fluid communication with the chamber. The nozzle is prepared by a process including the step of focusing a laser beam so that its focal point is located substantially on an outer surface of the tip portion for a first period of time sufficient to create the passageway whereby the nozzle is formed and a waste product is deposited at a periphery of the passageway. The process further includes the step of creating a first prepassageway which extends though the tip portion of the housing, the first prepassageway defining a first substantially cylindrically-shaped channel having a first diameter.