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SmalTec Micromachining Advancements

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SmalTec International
SmalTec International

SmalTec International is the world’s leading manufacturer of micromachining equipment for aerospace, communications, medical, automotive, optics, nanotechnology and other innovative industries.

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Micro EDM Technology Advancements
Outline ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International
Copyright © SmalTec International ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],EM203 Specifications Micro-EDM: EM203 and GM703 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],GM703 Specifications www.SmalTec.com
Spark Technology ,[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International
Copyright © SmalTec International Basics Behind the Technology Energy Discharge Relationship E= ½ CV² Roughing Energies: 100v/3300pF 16,500 nJ 90v/220pF 891 nJ Final Energies: 80v/100pF 320 nJ 70v/20pF 49 nJ Measuring Energies: 10V/10pF 500 pJ 2V/10pF 20 pJ 20pJ = 20*10 -12 Joules 1 AA Battery = 1x10 3 Joules 1 Spark Event = 5*10 -9 Seconds 1 AA Battery could power a 20pJ spark for 70 hours! 5ns pulse width Highest Frequency in the Industry
Edge Comparison Copyright © SmalTec International Energy – 49 nJ 5 ns Nearest Competitor Energy – 12,700 nJ 180 ns Recast 10 um scale Magnification
Tooling is Critical ,[object Object],Copyright © SmalTec International
WEDG Machining ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International
Applications That Work Well ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International
Applications That Work Well ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International “ SmalTec has done a great job in bringing Micro-EDM out of the niche applications into a machine shop process… [and] partnering with us to develop new applications” C.N. DeVore, Research Scientist , 3M Corporation
Inkjet Nozzle Plates Copyright © SmalTec International Material: SS Varieties Top diameter :58 μ m Tungsten Top diameter :32 μ m Tungsten Electrode
SEM/FIB Apertures Copyright © SmalTec International 5 um diameter Thickness: 50um Material: Platinum 5 um X 45 um Thickness: 100um Material: Platinum
Micro Wire Guide Copyright © SmalTec International 50 um Radius 10 mm Diameter 6 mm Material : SS 421
Copyright © SmalTec International Panasonic Φ100 um L= 500 um Cu sheet （ thickness 18 um ） Precision Punch Material : Copper
Micro Pins Copyright © SmalTec International Material : SS Music Wire
Material Tensile Test Piece Copyright © SmalTec International Material : SS 304
High Aspect Hole Copyright © SmalTec International Entry 132 um Exit 125 um 4.40 mm Tool path Material : Carbide
Process Specific Applications ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International *Ultrapure deionized water has a theoretical maximum resistivity of 18.31 MΩ·cm and a theoretical minimum conductivity of .0545 microsiemens(µS) /cm, compared to around 15 kΩ·cm and 70 (µS)/cm for tap water. 0.788 high 1.87 cSt EDM 185 0.793 high 2.8 cSt Ionoplus 3000 0.82 high 3.4 cSt EDM 30 Specific gravity Dielectric strength Viscosity Fluid name cSt=centistokes
Function of the Dielectric ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International
Metrology Capabilities ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International
Tungsten CMM Probe Copyright © SmalTec International 35 micron radius tip Radius formed by PCD tool diameter Future: stem lengthened with μ EDM process
Tungsten CMM Probe Copyright © SmalTec International 35 micron radius tip
Tungsten Carbide CMM Probe Copyright © SmalTec International 75 micron diameter tip 50 micron post width 1 mm post length
Copyright © SmalTec International Impact on Gold Surface Surface Mapping 200A of E-Beam Evaporated Gold on a Glass Slide Gold Glass
Surface Mapping of Gold Copyright © SmalTec International X Axis (mm) Z Axis 40v 30v 20v 10v 5v 2v 1 um
Copyright © SmalTec International No impact on surface using less than 10v and 1opF (<500pJ) Impact on Gold Surface
In Closing ,[object Object],[object Object],[object Object],[object Object],Copyright © SmalTec International “ Mechanical and electrical functions are getting more and more concentrated in a great part of industrial products…Micro-Machining is one of the important technologies which support this tendency” - Dr. T. Masuzawa
The Future Starts Here … For more information, please contact or visit us: SmalTec International 1998 Ohio Street Ste 200 Lisle, IL 60532 p: 630.364.1788 e: info@smaltec.com w: www.SmalTec.com

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SmalTec Micromachining Advancements

  • 1. Micro EDM Technology Advancements
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  • 5. Copyright © SmalTec International Basics Behind the Technology Energy Discharge Relationship E= ½ CV² Roughing Energies: 100v/3300pF 16,500 nJ 90v/220pF 891 nJ Final Energies: 80v/100pF 320 nJ 70v/20pF 49 nJ Measuring Energies: 10V/10pF 500 pJ 2V/10pF 20 pJ 20pJ = 20*10 -12 Joules 1 AA Battery = 1x10 3 Joules 1 Spark Event = 5*10 -9 Seconds 1 AA Battery could power a 20pJ spark for 70 hours! 5ns pulse width Highest Frequency in the Industry
  • 6. Edge Comparison Copyright © SmalTec International Energy – 49 nJ 5 ns Nearest Competitor Energy – 12,700 nJ 180 ns Recast 10 um scale Magnification
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  • 11. Inkjet Nozzle Plates Copyright © SmalTec International Material: SS Varieties Top diameter :58 μ m Tungsten Top diameter :32 μ m Tungsten Electrode
  • 12. SEM/FIB Apertures Copyright © SmalTec International 5 um diameter Thickness: 50um Material: Platinum 5 um X 45 um Thickness: 100um Material: Platinum
  • 13. Micro Wire Guide Copyright © SmalTec International 50 um Radius 10 mm Diameter 6 mm Material : SS 421
  • 14. Copyright © SmalTec International Panasonic Φ100 um L= 500 um Cu sheet （ thickness 18 um ） Precision Punch Material : Copper
  • 15. Micro Pins Copyright © SmalTec International Material : SS Music Wire
  • 16. Material Tensile Test Piece Copyright © SmalTec International Material : SS 304
  • 17. High Aspect Hole Copyright © SmalTec International Entry 132 um Exit 125 um 4.40 mm Tool path Material : Carbide
  • 18.
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  • 21. Tungsten CMM Probe Copyright © SmalTec International 35 micron radius tip Radius formed by PCD tool diameter Future: stem lengthened with μ EDM process
  • 22. Tungsten CMM Probe Copyright © SmalTec International 35 micron radius tip
  • 23. Tungsten Carbide CMM Probe Copyright © SmalTec International 75 micron diameter tip 50 micron post width 1 mm post length
  • 24. Copyright © SmalTec International Impact on Gold Surface Surface Mapping 200A of E-Beam Evaporated Gold on a Glass Slide Gold Glass
  • 25. Surface Mapping of Gold Copyright © SmalTec International X Axis (mm) Z Axis 40v 30v 20v 10v 5v 2v 1 um
  • 26. Copyright © SmalTec International No impact on surface using less than 10v and 1opF (<500pJ) Impact on Gold Surface
  • 27.
  • 28. The Future Starts Here … For more information, please contact or visit us: SmalTec International 1998 Ohio Street Ste 200 Lisle, IL 60532 p: 630.364.1788 e: info@smaltec.com w: www.SmalTec.com