This document summarizes Prodintec's micromilling technology capabilities. Micromilling is a high precision machining process that can create complex geometries with features as small as microns. Prodintec has equipment that can micromill a wide range of materials with a precision of 2 microns using CAD/CAM software and CNC programming. Their facilities include machines with precision positioning and measurement systems to control and verify the micromilling process.

1. PRODINTEC
MICROMILLING TECHNOLOGY

2. MICROMILLING
INTRODUCTION
Since 2005 PRODINTEC Foundation is working with machining technologies.
Micromilling was launched as key research line for the R&D Production
Department.

3. MICROMILLING
DESCRIPTION
Machining by means of metal removal at macro and meso scale is well-known.
Micromilling is the process at a lower scale presenting high accuracy for
geometries with the size of micra.
Micromilling tools are smaller therefore it is required to increase the speed
(rpm) in order to obtain high metal removements values. It is also called,
high speed mechanization.

4. MICROMILLING
DESCRIPTION
Micromilling stars with a CAD file of the piece. The file is processed using a
software CAM. The result is the generation of the process paths that will define
the required geometry considering the tolerance limits.

5. MICROMILLING
ADVANTAGES:
• Wide range of materials, steel up to HRC 65, stainless steels, ceramics
(green ceramic, pre-sintherized and sintherized ceramics), glass, plastic
materials, woods, resins, copper (electrods), graphite,...
• Complex geometries, 5 axes micromilling.
• Automatic process by means of CNC programing.
• Tolerance ±2 µm.
• Accurate control of machining process by means of a non-touching laser
control of tools.

6. MICROMILLING
PRODINTEC FACILITIES:
The equipment is a KERN machine (Evo model) with the following
characteristics:
X/Y/Z: 250/250/200 mm
Maximum piece load: 50 kg.
Speed: 0,01-16.000 mm/min
8 m/s2
Resolution: 0,1 µm
Position precision: 0,5 µm VDI/DGQ 3441
Roughness Ra < 0,1 µm

7. MICROMILLING
PRODINTEC FACILITIES:
Available screws: 1 unit until 50.000 rpm. (Maximum tool diameter 8 mm); 1
unit until 160.000 rpm (Maximum tool diameter 3 mm)
Division tool for 4º/5º axe with a positioning precision of 1”
Automatic system for tools with 32 positions
Tool calibration with laser measurements (BLUM) with calibration pin.
Touching Infrared technology
Optical microscope
Cooling with oil and spray oil
Computer Numerical Control (CNC): Heidenhain iTNC 530
Concrete base: anti-vibration system
Cooling room with temperature and moisture control (20º±0,5º)

8. MICROMILLING
EXAMPLES
Microdrilling (Ø200 µm) AISI-316 Nanostructured ceramic
Lexan samples Stainless steel for thermoplastic inserts

9. MICROMILLING
EXAMPLES
TOPAS sample Microtexturing
3000 micro-holes Ø200 µm Medical screw

10. MICROMILLING
MEASUREMENT AND CONTROL SYSTEM
MMC Zeiss model Contura G2
Measurement volume: 1.000x1.600x850 mm
Tactile measurement system (synthetic ruby) precision of measurement 0,1 µm uncertainty
1,9 µm en 300 mm
Optical measurement system (VISCAN 4x) precision 0,1 µm e uncertainty 10 µm (VDI/VDE
2617)
Touch probe VAST XXT TL1 ID
Automatic change of touch probes with 7 positions including VISCAN camera
Software Calypso CNC Geometry 4.4
ENAC certificate of calibration
Cooling room with temperature and moisture control (20º±0,5º)
Perfilómeter óptic SOLARIUS model Viking
The tool is designed to meet mid range accuracy needs using state of the art sensor
technology to generate 3 dimensional surface maps.
Viking is a desktop general laser measuring tool consisting of an X/Y 100mm moving axis
platform mounted below a laser sensor to provide fast non-contact profiling of a vast variety
of engineering surfaces and electronic components.
Cromatic sensors WLC2 range 300 µm, resolution 0,012 µm, accuracy 0,06 µm, spot 2,6 µm
and WLC4 range 2,5 mm, resolution 0,075 µm, accuracy 0,4 µm, spot 25,6 µm
Offset camera integrated with monitor
Motorised axes X/Y with a maximun movement range 100 mm each axe.
Software for analysis SolarMap 3D
Cooling room with temperature and moisture control (20º±0,5º)
Microscope estereoscopic Leica model M205A
Stereoscopic microscope Leica (M205A model) with the following characteristics:
Optic 20,5:1 motorised
Zoom 7,8x a 160x
Resolution 525 Lp/mm
Visual field 29,5 mm a 1,44 mm
Lens 1,0x y 2,0x
Coaxial Led 5000 CXI
Digital camera Leica DFC 420 (5,0 Mpx with Firewire connection)
Measurement LAS
Vision system 3D LAS

11. PRODINTEC
Technological Research Center for the Design and Industrial Production
EDIFICIO CENTROS TECNOLÓGICOS
PARQUE CIENTÍFICO Y TECNOLÓGICO
33203 GIJÓN. ASTURIAS
T +34 984 390 060
F +34 984 390 061
www.prodintec.com