Swiss machining processes are commonly used for machining small parts due to their high precision and accuracy. These processes involve the use of specialized machines called Swiss screw machines, which are designed to handle small diameter parts with tight tolerances. Micromachining is another process that is used for machining small parts, often at a sub-millimeter scale. Other machining processes like CNC milling and turning, EDM/WEDM can also be used for small part production, but may not offer the same level of precision and efficiency as Swiss machining. Ultimately, the choice of machining process will depend on the specific requirements of the part and the production volume needed.
Falcon Swiss combines 5-axis small part machining and multi-axis CNC Swiss lathes to produce components where micron-level accuracy defines performance. With 300+ advanced CNC systems and ISO 13485/IATF 16949 certifications, we specialize in:
Medical & Biotechnology
Micro-machined medical components: Titanium orthopedic fasteners (ASTM F136) with Ra0.2μm electropolished surfaces, ensuring biocompatibility for spinal implants.
PEEK microfluidic valves: 0.5mm channels ±0.005mm accuracy, sterilizable at 135°C for drug delivery systems.
Automotive & Electronics
Automotive sensor housings: Aluminum 6061-T6 ABS modules with IP67 sealing, tested to 50G vibration loads.
High-volume screw machining: C36000 brass terminals for EV charging ports, 500k+/month batches with ±0.002mm thread consistency.
Optical & Industrial
Optical alignment pins: 316L stainless steel dowels with <0.5μm concentricity for laser collimators.
Inconel 718 nozzles: Wire EDM-cut for aerospace fuel systems, tolerating 1,200°C/15,000psi.
Technical Edge
Material Mastery: 475+ materials, including Nitinol, Ultem 2300, and Kovar.
Secondary Operations: Zinc-nickel plating (MIL-STD-202F), micro-arc oxidation (50μm ceramic coatings).
Quality Assurance: 100% CMM inspection, PPAP Level 3 documentation, and 24-hour rapid prototyping.
Falcon’s Swiss screw machines and 5-axis machining systems produce complex miniature components with ±0.002mm tolerances for industries where micro-scale accuracy drives success. Specializing in medical, automotive, and optical applications, we machine 475+ materials—from titanium (Ti-6Al-4V) to high-conductivity copper (C17200)—to meet stringent performance demands.
Key Capabilities
Medical & Dental
Titanium machined bone screws: Ø1.5mm±0.002mm with Ra0.2μm electropolished surfaces (ASTM F136 compliant).
PEEK surgical tool components: 0.5mm micro-channels for laparoscopic devices, sterilizable at 135°C.
Automotive & Electronics
EV battery contact pins: C17200 brass terminals with 18μΩ·cm conductivity, batch-produced at 500k+/month.
ABS sensor housings: Aluminum 6061-T6 parts IP67-certified for water/dust resistance.
Optical & Industrial
Fiber optic alignment sleeves: 316L stainless steel, <0.5μm concentricity for 5G transceivers.
Inconel 718 nozzles: Wire EDM-cut for aerospace fuel systems, tolerating 1,200°C/15,000psi.
Technical Edge
Swiss screw machining: Handles Ø0.8mm-32mm diameters, L/D ratios up to 30:1.
Secondary operations: Zinc-nickel plating (MIL-STD-202F), micro-arc oxidation (50μm Al₂O₃ coatings).
Certifications: ISO 13485 (medical), IATF 16949 (automotive) with full PPAP/FMEA documentation.
Falcon’s Swiss machining expertise transforms raw materials into mission-critical components for industries where micron-level precision is non-negotiable.
1. Medical & Surgical Innovations
Titanium bone screws: ASTM F136-compliant, Ø1.5mm±0.002mm with electropolished Ra0.2μm surfaces for reduced infection risk.
PEEK surgical tool handles: Micro-milled 0.4mm fluid channels, autoclave-safe at 135°C for laparoscopic devices.
Catheter guidewires: Nitinol shafts with <0.005mm diameter consistency, enabling minimally invasive procedures.
Certification: ISO 13485 with full material traceability (Lot No. tracking) and FDA audit support.
2. Aerospace & Defense Systems
Fuel injector nozzles: Inconel 718 components wire EDM-cut to ±1μm slot tolerances, tested at 1,200°C/15,000psi.
Hydraulic valve spools: 316L stainless steel, 500-hour salt spray resistance for UAV actuators.
Titanium sensor housings: 5-axis machined to IP68 standards for satellite altitude control systems.
3. Electronics & 5G Infrastructure
RF connector pins: C17200 copper alloy contacts with 18μΩ·cm conductivity, ensuring 28GHz signal integrity.
Micro-diameter terminal pins: Brass C36000 pins (Ø0.3mm) for IoT sensors, plated with 8μm Au-Ni for corrosion resistance.
4. Precision Timekeeping Components
Swiss watch balance wheels: 18K gold alloy gears with <0.5μm radial runout, tested to 50,000 cycles.
Chronograph screws: 440C stainless steel, hardened to 58 HRC for luxury timepiece assemblies.
Technical Edge
Materials: 475+ options, including Kovar, Ultem 2300, and ZrO₂ ceramics.
Secondary ops: Zinc-nickel plating (MIL-STD-202F), laser marking (UID compliance).
Quality: 100% CMM inspection, 24-hour rapid prototyping, and PPAP Level 3 documentation.
At Falcon CNC Swiss, holding ±0.001mm tolerances on miniature components isn’t aspirational—it’s operational standard. Here’s how we ensure precision for industries where failure is not an option:
1. Medical-Grade Accuracy
Titanium bone screws (ASTM F136) with Ra0.2μm electropolished surfaces, reducing biofilm risk in spinal implants.
PEEK microfluidic valves: 0.4mm channels ±0.005mm accuracy, validated through 1,000+ autoclave cycles (135°C).
2. Aerospace Reliability
Inconel 718 fuel nozzles: Wire EDM-cut slots at ±1μm tolerance, tested at 1,200°C/15,000psi for jet engines.
Titanium sensor housings: 5-axis machined to IP68 standards for satellite thermal-vacuum environments.
3. Technical Edge
Equipment: Tornos Swiss lathes with 0.1μm-resolution servos and 50,000 RPM spindles.
Process Control: Real-time laser measurement systems ensuring 99.8% batch consistency across 500k+ units/month.
Certifications: ISO 13485 (medical), IATF 16949 (automotive) with full PPAP/FMEA documentation.
Why Precision Matters
Zero Defects: 100% CMM inspection eliminates errors in Ø0.3mm catheter guidewires and 5G RF connectors.
Cost Efficiency: Reduced scrap rates (under 0.2%) through adaptive toolpath optimization.
Get your customized precision parts solution now →
ISO 13485 certification guarantee | ± 0.001mm tolerance | 15 days global delivery
When producing small parts using Swiss machining, even the slightest error can cause significant problems. Precision machining ensures that the parts are manufactured to extremely tight tolerances, leaving little room for error. This reduces the risk of errors occurring and ensures that the parts fit together perfectly in the final assembly.
Small parts produced through Swiss machining are commonly used in industries where precision and reliability are essential, such as aerospace, medical, and defense. In these industries, even the slightest deviation from the required specifications can cause a product to fail. Swiss machining ensures that the parts are produced with the utmost precision and are capable of withstanding even the most rigorous applications.
Precision machining reduces the number of defective parts produced during the manufacturing process. Swiss machining is highly accurate and produces parts with very tight tolerances, minimizing the risk of producing defective parts. This, in turn, reduces the need for costly rework and delays in production.
Precision machining requires the right equipment and expertise. Falcon Multi-spindle Swiss machining equipment is highly specialized and requires skilled operators to ensure that the parts are manufactured to the required specifications. This expertise ensures that the parts are produced with the required level of precision.
Precision is critical in Swiss machining and Micromachining because small parts often have intricate geometries and require tight tolerances to function properly. Swiss machining is ideal for producing such parts because it can achieve high levels of precision and accuracy.
In Swiss machining, the cutting tool moves along the length of the material, removing small amounts of material with each pass. The process is repeated until the desired shape and size of the part is achieved. Because the cutting tool is so small, it can remove material with high precision, producing parts with very tight tolerances.
Small parts that are produced with tight tolerances must fit together perfectly in the final assembly. For example, in medical devices, small parts may need to fit together with other components to form a complex mechanism that must work together flawlessly. If the parts are not manufactured with the required level of precision, they may not fit together properly, causing the entire mechanism to fail.
In addition, small parts that are produced with tight tolerances may be used in critical applications where safety is a concern. For example, in aerospace applications, small parts may be used in aircraft engines, where even the slightest deviation from the required specifications could cause catastrophic failure.
CNC machining small parts can present several challenges due to the precision and accuracy required for their manufacture. Some of these challenges include:
1. Maintaining dimensional accuracy: Small parts require tight tolerances and high accuracy, which can be challenging to achieve due to the complexity and small size of the parts.
2. Tool selection and durability: The selection and durability of cutting tools become critical for small parts to avoid tool wear and breakage that can affect the quality of the finished parts.
3. Workholding: Holding small parts securely and accurately during machining is challenging as there is limited space to clamp the parts and ensure they don't move or shift.
4. Chip management: With limited space for chips to exit the machining area, chip buildup can be an issue, leading to tool wear, cutting edge damage, and surface finish issues.
5. Programming complexity: Small parts may require complex and intricate programming to achieve the desired geometries and features, which can be challenging to achieve with high accuracy and repeatability.
Small metal parts can be made using various manufacturing processes, including Swiss machining and micromachining. CNC Swiss precision machining is a precision machining process that uses a sliding headstock lathe to produce small, complex metal parts. The process involves feeding long bar stock through a guide bushing to the cutting tool, allowing for precise and continuous machining. Swiss machining is ideal for producing small parts with intricate features and tight tolerances, such as those used in medical devices, aerospace components, and watchmaking. Micromachining, on the other hand, uses small cutting tools and high-speed spindles to produce very small metal parts. It is ideal for producing very small and precise parts, such as those used in microelectronics, medical devices, and aerospace components. The choice of process depends on the specific requirements and features of the part being produced.
CNC micro machining is a specialized manufacturing process used to produce small and precise parts with high accuracy and repeatability. The process involves the use of computer-controlled machines with very small cutting tools and high-speed spindles to produce parts with dimensions ranging from micrometers to a few millimeters. CNC precision micro machining is typically used to produce parts for microelectronics, medical devices, aerospace components, and other industries that require small, intricate, and precise parts. The process involves precise tool positioning, high spindle speeds, and advanced software programs to produce complex geometries and features with high precision and accuracy. CNC micro machining is essential for the production of miniature components that require high tolerances, intricate features, and complex shapes.
