​What is the Micro Machining Process? A Comprehensive Guide to Ultra-Precision

Micro machining enables the creation of components smaller than a grain of table salt with tight tight tolerances. At Falcon CNC Swiss, we combine Swiss machining expertise with advanced micro-machining technologies to craft mission-critical parts for medical, electronics, and automotive industries. Here’s how this process transforms raw materials into microscopic marvels.

1.What Is the Micro Machining Process?

Micro machining refers to manufacturing parts with features under 1mm in size, using specialized techniques that surpass traditional machining limits. Unlike conventional methods, it employs:

• Mechanical Micro Machining: Micro drills (Ø0.1mm) and mills on Swiss CNC machines.

• Laser Micro Machining: Femtosecond lasers for 0.005mm surface texturing.

• Electrochemical Machining (ECM): Dissolves metals ion-by-ion for burr-free edges.

• Ultrasonic Machining: 40kHz vibrations to shape brittle materials like zirconia ceramics.

2.How Micro Machining Works

Step-by-Step Process

Design: CAD models define 0.05mm features like neural probe channels.

Tool Selection: Diamond-coated micro end mills (Ø0.05mm) for titanium implants.

Machining: Swiss CNC lathes with guide bushings stabilize Ø0.3mm rods during cutting.

Inspection: White light interferometry validates Ra 0.1µm finishes.

Key Technologies:

5-Axis Swiss CNC: Machines vascular stents with 0.1mm lattice structures.

Laser EDM: Drills Ø0.03mm holes in fuel injector nozzles.

3.Materials Used in Micro Machining

Exotic alloys like Nitinol are also machinable for shape-memory devices.

4.Applications of Micro Machining

Medical Devices

Biodegradable Screws: Magnesium alloys dissolving in 6–12 months.

Surgical Robotics: Ø0.8mm wristed tools with 0.001" flex tolerance.

Electronics

5G Antennas: Gold-plated brass connectors with 0.05mm pitch.

Automotive

Fuel Injectors: Nozzles with 0.1mm micro-channels.

5.Advantages of Micro Machining

Micro Machining Precision: Achieves ±0.0005" for cochlear implant electrodes.

Material Efficiency: 98% utilization vs. 80% in traditional CNC.

Complex Geometries: 5-axis Swiss CNC machines cardiac stent lattices in one setup.

Disadvantages

Cost: Swiss CNC machines exceed 500k, withmicro−tools costing500k, withmicro−toolscosting200+/each.

Tool Wear: Diamond mills last 8k parts vs. 50k in macro machining.

Accuracy Comparison

Laser micro machining achieves Ra 0.5µm finishes on PEEK.

6.Choosing a Micro Machining Partner

Key Considerations

Certifications: ISO 13485 for medical devices.

Equipment: 7-axis Swiss CNC with sub-spindles.

Materials: Expertise in Ti-6Al-4V and bioresorbables.

Why Falcon CNC Swiss?

300+ Machines: Producing 1.7M micro components weekly.

CT Inspection: Guarantees 0-defect surgical screws.

7.Conclusion

Micro machining powers innovations from neural probes to micro-optics, demanding unparalleled precision. Falcon CNC Swiss combines Swiss machining heritage with cutting-edge technology to deliver components where microns matter.

Request a Free Precision Assessment Today!