Initial Situation

High production costs and a limited choice of technologies, materials and geometries are currently hindering more widespread application of micro system technologies, although the market is already there.

Moulds for Forms with Optical Surfaces

Existing machining techniques permit the manufacture of non-ferrous form segments with accuracies in the sub-micro scale. Yet, typical lead times are up to six months, even for small segment inserts. It is not possible, at the moment, to manufacture large and sculptured tool inserts with optical microstructures made of steel.

Moulds for Filigree Mechanical Parts

Existing tool making process chains must be scaled down for the manufacture of moulds for micro applications. Unfortunately, the scaling down process itself, has effects that lead to changes other than the purely geometrical downscaling. Generally speaking, milling, EDM and Wire EDM are not yet able to guarantee the required level of process reliability.

Moulds for Small Micro Structured Parts

Further super finishing processes are required to create superior surface qualities on small micro structured parts. Currently, manual techniques prevail. Automated, NC-controlled polishing requires further development for complex shapes.

There are additional fundamental problems in connection with the creation of a closed process chain: Transporting parts from one machining operation to the next often cause losses in accuracy. Furthermore, current CAx-systems have not yet been adapted to deal with the constraints of micro production. Finally, the lack of technology databases make product development in this field extremely difficult.

Objectives

In this Case Study, the partners are qualifying and developing mould and tool manufacturing techniques for micro and precision applications. The aim is to enable the development and production of highly integrated complex products at reasonable costs.

Solutions

Creation of a comprehensive technology knowledge data basis for existing and new manufacturing technologies

Assessment and classification of machining techniques like micro milling, precision grinding, ultrasonic-assisted diamond ma- chining of steel, micro sink- and wire-EDM, laser curing and polishing

Development of specialised CAD/CAM solutions for micro and precision engineering and manufacturing

Integration of manufacturing know-how in product development processes

Improvement of manufacturing tools and processes

Optimisation of machine tools and manufacturing equipment

Development of environmentally-friendly techniques