A composite structure containing a nozzle layer and an adhesive layer is provided and the adhesive layer is coated with a polymeric sacrificial layer. The coated composite structure is laser ablated to form one or more nozzles in the structure and the sacrificial layer is removed. The sacrificial layer is preferably a water soluble polymer, such as polyvinyl alcohol or polyethylene oxide, which is removed by directing jets of water at the sacrificial layer until it is substantially removed from the adhesive layer.