With the increasing demand for miniaturized devices, micromanufacturing techniques have become essential for mission-critical industries, medtech , aerospace, space exploration, and defense. This highly specialized manufacturing process makes it possible to produce small and intricate parts with dimensions in the micrometer range (less than 1 millimeter). Often, the parts are so small that many people question whether they were really machined or if they were micro-molded!
Micromanufacturing advances are critical to saving lives and improving quality of life. In this post, we explore a few of the latest micromanufacturing techniques we use and provide examples of components each precision technique can produce. But first, let us explain why we’ve invested in micromanufacturing with the following list of advantages to using this specialized manufacturing process.
Benefits of Micromanufacturing
Micromanufacturing can help solve seemingly insurmountable manufacturing challenges, offering a precise solution for the world’s smallest components. Here are the benefits:
- High precision: Micromanufacturing processes lend a higher level of precision to accommodate the fine features of micro-sized parts.
- Complex geometries: Micromanufacturing processes can produce complex geometries with high precision and accuracy, such as diameters, pockets, slots, and holes.
- Customization: Micromanufacturing processes can be highly customized to meet specific design requirements, allowing us to produce unique components with specialized features.
- Scalability: Micromanufacturing processes can be easily scaled up or down to produce parts and components of different sizes, making it a flexible manufacturing solution that adapts to changing production needs.
- Wide range of materials: Multiple processes used to micromanufacture components can be applied to many different materials, including metals and composites, allowing us to produce various miniaturized parts and components for different industries.
- High speed: Some micromanufacturing techniques, such as micromachining, microgrinding, and micro EDM, can produce complex geometries quickly.
The Latest Micromanufacturing Techniques
Many micromanufacturing techniques can produce a small and intricate part, and each method has unique advantages and considerations, depending on your application and part requirements. Below, we’ll introduce you to a few of our highly specialized micromanufacturing techniques and the extremely precise components they help us produce.
Micro Swiss Machining
Micro Swiss machining is a specialized extreme precision micromanufacturing technique used to produce small, complex parts with high accuracy, repeatability, and surface finish. Expert craftspeople produce micro-sized parts utilizing small cutting tools, high RPM tooling spindles, with high precision micro collet systems to produce parts that combine turning and milling. This micromachining technique can perform multiple operations in a single setup, reducing production time and increasing efficiency in a repeatable process. Our highly skilled micro Swiss machining operators use this specialized technique to produce miniaturized parts like small, screws, fasteners, connectors, and technical components with intricate shapes and features.
Micromilling
Micromilling is like conventional milling but on a smaller scale, with cutting tools less than 0.05 mm in diameter. This micromachining technique involves cutting materials with very small endmills and drills as small as .002” dia to produce very small parts and features in materials like aluminum, stainless steel, and titanium, with high precision accuracy. We use micromilling to create features with micron tolerances and low Ra surface finishes for components, such as microelectromechanical systems (MEMS), microfluidic devices, miniature bearings, connectors, sensors, actuators, and medical and dental implants.
Microgrinding
Microgrinding is a precision centerless grinding process that produces small parts and features with extremely high accuracy and surface finish. The process involves removing material from a workpiece using a rotating abrasive wheel with very small grit sizes, typically 1 to 10 microns in diameter. Microgrinding can create features with tolerances in the sub-micron range, making it ideal for applications requiring tight tolerances. Our craftspeople use microgrinding to produce tiny, precise parts, such as guidewires, microelectromechanical systems (MEMS), optical components, and miniaturized bearings.
Micro EDM
Micro EDM is a specialized micromanufacturing EDM technique involving using the electrical discharge machining process to remove material from a workpiece, producing parts with high accuracy and surface finish, even on hard, brittle materials that are difficult to machine using other techniques, such as conductive materials such as tungsten, tungsten carbide, and hardened steel. The CNC machinery used, and the tolling designed and created, must be specialized for these applications, allowing the proper wire tensioning, auto threading of small wires, low power supplies, and sensitivity in the cut. However, the thickness of the parts will limit the wire EDM application performance. Generally, we have found that the part thickness limit is approximately 1”. Micro RAM EDM is also possible, depending on the application requirements. Examples of parts we’ve produced using micro EDM include miniature gears, MEMS, micro surgical tools and implants, and micro tools.
Learn more about the differences between Wire and RAM EDM on our blog.
Accuracy is Critical for Micromanufacturing Success
Like other precision manufacturing methods, micromachining and microgrinding require holding many geometric features to sub-micron levels to ensure each part’s accuracy, safety, and performance. We rely on high-end metrology inspection equipment, such as vision systems, laser micrometers, form & cylindricity testers, and optical sensors, to validate our results, providing proof and peace of mind. Learn more about the five types of metrology inspection equipment we use for maximum accuracy and precision.
The world’s smallest parts require micromanufacturing excellence – and our results speak for themselves. Head to our website to learn more about our micromachining and microgrinding capabilities, or contact our team for personalized assistance.
