Micro Manufacturing Magazine

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Micromachining
Watch a 3-minute video of a microlaser
platform developed at Finlands Tampere
University of Technology. The platform
accepts several different lasers and has a
single-axis velocity of up to 2,400mm/sec.
with acceleration up to 2g.
micro.delivr.com/141ui
3-D laser system
Slovenian researchers recently demon-
strated full 3-D tunable lasing in laser dye-
doped cholesteric liquid-crystal microdro-
plets from 15m to 50m in diameter. A
brief video shows the process in action.
micro.delivr.com/141uf
Sprue separator
ALBA Enterprises offers a quick video
demonstration of its sprue separator, which
is said to address a common problem
among micro-injection moldersseparating
the runners from the good parts.
micro.delivr.com/141u9
On MICROmanufacturing.com
COLUMNS
4 Front Page
Don Nelson,
Publisher
Manufacturing shows signs
of life.
12 Measurement Matters
Susan Woods,
Contributing Editor
Strain gages for measuring and
testing microparts.
14 Micromachining
Alan Richter,
Senior Editor
Spindle developments for
micromachining.
16 Laser Points
Ronald D. Schaeffer,
PhotoMachining Inc.
Using gas to improve laser
machining.
19 Down Sizing
Dennis Spaeth,
Electronic Media Editor
MEMS microphones.
48 Last Word
Dr. Alissa Fitzgerald,
A.M. Fitzgerald &
Associates LLC
Machinist heritage key to
MEMS future.
DEPARTMENTS
6 Tech News
46 Products/Services
47 Advertisers Index
48
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Dennis Spaeth
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2 | JANUARY/FEBRUARY 2011 | MICROmanufacturing
Cover Story
22 Implant Nation
William Leventon,
Contributing Editor
Implantable medical-device
market growth aided by
microparts.
28 Swiss-Style Success
Glen Crews,
Marubeni-Citizen Cincom,
and Bill Kennedy,
Contributing Editor
Tools, tactics and tips for
productive Swiss-style
micromachining.
33 Rotary Burn
Alan Richter, Senior Editor
A rotary axis turns a wire EDM
into a lathe.
38 Spinning Tale
Dr. LaRoux K. Gillespie
Electrospun bers exhibit
incredible strength.
ON THE COVER:
Cover design by Tom Wright.
38
22
33
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Don Nelson
Publisher
M
anufacturing stinks. Ive heard that
blunt assessment of the U.S. indus-
trial sector plenty of times over the past
3 years. To all those whove uttered those
wordsor even blunter appraisalsI oer
a small measure of comfort: Manufacturing
stinks less now than it has in a long time.
Te latest government and industry statis-
tics show:
New orders rose 0.7 percent in

November 2010, the fourth increase in 5
months. (Excluding the transportation sector,
new orders grew 2.4 percent.)
Shipments climbed 0.8 percent in

November, the third consecutive monthly
increase.
Te December 2010 Purchasing

Managers Index registered 57 percent,
a 0.4 percent rise and the 17th straight
month above 50 percent. (Fifty percent is
the boundary line separating an expanding
economy from a contracting one.)
Plant capacity reached 71 percent in the

third quarter of 2010, up 2.3 percent over the
second quarter and 5.5 percent higher than
the same period in 2009.
Manufacturing jobs inched up 1.2

percent in 2010to roughly 11.7 million
the rst increase since 1997.
In a recent article in Te Wall Street
Journal, economists predicted that the U.S.
would add approximately 330,000 manufac-
turing jobs in 2011. Tat certainly wouldn't
come close to osetting the 6 million jobs lost
since 1997, but it could indicate the bleeding
has been staunched.
Most of the manufacturing jobs lost the
past 15 years wont be coming back. Tis is
due to aggressive oshoring of production
by American companies and to technolog-
ical advancements that have signicantly
raised U.S. workers productivity. From 1997
through 2009, factory productivity rose 54
percent, according to the Bureau of Labor
Statistics.
Another factor limiting U.S. job growth is
the changing nature of manufacturing itself.
Twenty years ago, we were looking at
big companies that carried on almost all of
their activities within their own four walls,
said Massachusetts Institute of Technology
Prof. Suzanne Berger during a recent inter-
view on National Public Radio. Everything
from research and development to design
to production and on through distribution.
Whats happened is that production does not
take place within the four walls of a single
company anymore. Te world of production
has been completely broken up into indepen-
dent companies. Engineers and technicians
can be located thousands of miles apart.
Tis has led to the formation of manufac-
turing rms that have never manufactured
anything. Tey design and prototype prod-
ucts, then outsource production to other
companies.
MITs Industrial Performance Center
a research group dedicated to the study of
manufacturing innovation, productivity
and competitivenessis looking at how the
disconnect between design and production
will aect U.S. manufacturing in the future.
Specically, the group wants to examine the
impact of losing the wealth of design inno-
vations that occur during the manufacturing
process.
I think as we look [at] new technologies,
said Berger, author of How We Compete and
co-author of Made In America, were going
to see a lot of areas where keeping manufac-
turing closer to R&D and to design is going
to be essential if we want to produce good
products.
Keeping production nearby would also be
good for the U.S. economy in a multitude of
ways, including the creation of well-paying
and much-neededjobs.
Publisher
MICROmanufacturing
Telephone: (847) 714-0173
E-mail: dnelson@jwr.com
Fresh winds blowing through manufacturing
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Horizontal nanowire
growth process yields
nanoLEDs
While rening a novel method for
making nanoscale wires, chemists at
the National Institute of Standards and
Technology (NIST) discovered a bo-
nusnanowires that produce light sim-
ilar to that from light-emitting diodes.
Tese nanoLEDs may someday have
their light-emission abilities put to work
in microdevices such as nanogenerators
or lab-on-a-chip systems.
Typically, zinc-oxide nanowires are
grown vertically by chemical vapor de-
position of molecules from a gas onto
a base material. NIST chemists Babak
Nikoobakht and Andrew Herzing de-
veloped a surface-directed method for
growing zinc-oxide nanowires horizon-
tally across a gallium-nitride substrate.
Te technique uses gold heated to 900
C to catalyze crystal formation.
Te scientists discovered that a cata-
lyst thickness of about 20nm produced
nanowires that grew a shark-like dorsal
n (referred to as a nanowall) with an
electron-rich zinc-oxide portion and an
electron-poor gallium-nitride portion.
Te interface between these two mate-
rialsknown as a p-n heterojunction
allows electrons to ow across it when
charged with electricity. Te movement
of the electrons produced light and led
the researchers to dub the structure a
nanoLED.
According to the NIST scientists,
the horizontal-growth method makes it
easy to locate individual heterojunctions
on the surface. Microscopic examina-
tion of the nanostructures also revealed
few structural defects and distinct p-n
heterojunctions in the nanowalls.
Te researchers are using the pro-
cess to grow zinc-oxide nanowires on
dierent substrates, including sapphire.
Sapphire, by its nature, is not electri-
cally conductive, said Nikoobakht. So
we grow zinc-oxide wires on it, then
overcoat the wires with Group II-VI
semiconductor materials such as zinc
sulde, cadmium sulde and cadmium
selenide. Te idea is to allow tuning of
the wavelength of the nanoLED emis-
sions to cover a broader spectrum from
the UV region to near-IR wavelengths,
he explained.
Te researchers hope nanoLEDs will
lead to development of high-e ciency
solar cells, light sources and detectors.
Jim Destefani
Book covers microfuidics
fabrication techniques
Selection of the correct fabrication
method is a key to producing microu-
idic devices that meet desired applica-
tion requirements, according to John
Lee and Narayan Sundararajan, the co-
authors of a new book called Microfab-
rication for Microuidics.
Te application is importantit
drives everything, said Lee, associate
professor of Mechanical & Aerospace
Engineering, San Jose (Calif.) State Uni-
versity. But as far as which fabrication
process youre going to use, selection is
often more immediately inuenced by
the lower-level functions you wish to
perform.
Te book categorizes diverse
and numerous microuidic func-
tions under three main headings:
ow control within enclosed cavi-
ties and conduits, manipulation
of particles and cells, and ejection
of uids in the form of droplets or
sprays.
Te intended function inu-
ences the geometry required in
a microuidic device, Lee ex-
plained. For example, for uid
ejection, a very common geomet-
ric feature would be an orice per-
pendicular to a planar surface for
a droplet generator. Strategies for
fabricating such an orice may be
quite dierent from approaches to
making a pattern of conduits that
lie within a plane for microchannel
separations. So the function inu-
ences the required geometry and
properties, which, in turn, dictate
the fabrication processes and best-
suited materials.
Medical diagnostics and related
biological applications for micro-
uidics receive the greatest attention
in the book. Other applications include
pollution-control devices that allow
rapid, on-site analysis of contaminants
and toxins, and microuidic devices that
help control fuel cells, Lee said. Potential
growth areas include fabrication of mi-
crouidics from multifunctional materi-
als, such as electroactive polymers and
chemo-responsive materials, he added.
J. Destefani
Fabricating under the
microscope
Micromanufacturers typically use
microscopes for post-production evalu-
ation and inspection of parts, but one
company has developed a system that
makes a microscope part of the produc-
tion process.
Teem Photonics 3-D Micro Fabrica-
tion Module incorporates a nanosecond
Nd:YAG laser (1,064nm or 532nm, up
to 40kHz, 0.5ns) attached to a micro-
scope. Te system relies on two-photon
polymerization to fabricate parts.
NIST
Illustration at top shows a single row of nanowires
(cylinders with red tops) with fin-shaped
nanowalls extending outward. Optical micrograph
above shows rows of nanoLEDs emitting light.
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In TPP, ultrashort laser pulses selec-
tively polymerize a negative photosen-
sitive material, or selectively break the
polymer chain in a positive photosensi-
tive material. Molecules of the material
absorb only two photons of laser light,
hence the name. (To learn more about
TPP, see the July/August 2010 cover
story in MICROmanufacturing at www.
micromanufacturing.com.)
Te Teem Photonics system was de-
signed to fabricate part features as small
as 2m, with 200nm resolution, though
it has produced 1m features with
100nm resolution. Te smallest feature
produced to date is 20nm. Typical fea-
tures include pillars 2m in diameter
and 30m high, and slots 20m deep
and as narrow as 2m.
Te 3-D Micro Fabrication Module
combines three elements: Teem Pho-
tonics green Q-switched nanosecond
laser, a piezoelectric sample-positioning
stage with nanoscale accuracy, and pro-
prietary Simpoly fabrication software.
Te module has a work envelope of
100m 100m 100m. An optional
system is available that enlarges the en-
velope to 300m 300m 300m.
Users watch the process via a camera,
which is part of the system.
Te module accepts 3-D scan les or
CAD les (SolidWorks or AutoCAD,
for example). Te systems
software develops the laser
path and controls the slic-
ing that creates a product,
layer by layer. Te user de-
nes laser output power,
time per part and the speed
of the sample as it moves
past the lasers focal point.
Te software allows users
to produce one or more
parts per cycle.
Te 3-D Micro Fabrica-
tion Module costs $50,000.
According to Denis Bar-
bier, Teem Photonics chief technology
o cer, it takes a day to install the equip-
ment and software and train users.
Te system requires a microscope,
which can be purchased independently
or as part of the system. Te cost of an
appropriate microscope is estimated at
$20,000, bringing the total system cost
to $70,000. Any brand of microscope
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can be used, provided it is an inverted
microscope with a 100-percent port se-
lector, for eye safety. Teem Photonics of-
fers the Olympus IX51 microscope with
its system.
Te 3-D Micro Fabrication Module
can be used to produce microuidic
and MEMS devices, microelectronics
and nanophotonics. Plus, TPP has the
potential to make negative-index optical
devices. Biological applications include
the production of protein-based, arti-
cial, extracellular matrices and bioassay
chips. Te process has also been proven
eective in microencapsulation and the
production of microcantilevers, pho-
tonic crystals, microneedle arrays and
prototype micromolds.
Products have been made from ma-
terials such as silver, aluminum, gold,
tungsten, copper, ceramics, indium tin
oxide, acrylics, polyethylene, epoxies,
Ormosil (a photopolymer) and zirco-
nium sol-gel. (Te metals are combined
with resins in various ways or used to
coat a completed polymerized struc-
ture.) Photosensitive materials can be
added to many polymers to make them
more sensitive to the lasers UV light.
Dr. LaRoux K. Gillespie
Editors Note: For more information,
contact Denis Barbier, Teem Photonics,
Meylan, France. Telephone: 011 33 476-
040506. Web: www.teemphotonics.com.
In the U.S., contact: Jacques Bourgoin,
director of sales, Americas, Teem Pho-
tonics, Milipitas, Calif. Telephone: (408)
935-8390.
Lights, camera, micro!
Micromanufacturing requires spe-
cial lighting considerations. Measuring
dimensions typically calls for dierent
lighting than checking for stains, dust or
surface-nish quality. (Detecting solvent
stains may require dark-eld microsco-
py, which excludes the unscattered light
beam from the image.) Diuse light re-
duces eyestrain, but it also reduces the
ability to see defects, such as burrs and
texture dierences.
Te equivalent of cleanroom light-
ing should be the goal for most micro-
manufacturing operations, according to
Paul Varni, president of American Clean
Rooms, Rancho Santa Margarita, Calif.
(Te companys modular cleanrooms
are illuminated with 75 foot-candles of
light; the light in an average o ce is 50
foot-candles.)
Detecting burrs requires a strong light
that casts shadows, but the light must
be positioned so it does not reect into
the technicians eyes. Incident angles of
incoming light also aect the ability to
read markings and capture them with
cameras. Te optimal incident angle de-
pends on surface roughness and the de-
gree of shininess and transparency. For
example, when inspecting integrated
circuits, an incident angle of 75 is best
for high-surface-roughness parts; for
metals with moderate roughness, 60
is recommended. If the background is
white, using lights at both 15 and 60 is
recommended.
Te ideal lighting arrangement for
micro work is two or more illumina-
tion sources that provide diuse light
for much of the work, but allow the
user to cast shadows when and where
needed. Small uorescent and incan-
descent units for workbenches are avail-
able with exible heads. When using a
microscope, side-positioned incandes-
cent lights, combined with uorescent
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Lighting issue Preferred solution
Detect stains UV light, dark eld microscopy
Detect burrs Lights that cast shadows
Detect surface texture changes Lights that cast shadows
Disinfect surfaces UV light
Measure SiO
2
lm thickness Fluorescent light
Count parts Fluorescent light
Reduce eye fatigue Fluorescent light, LEDs
Deep microholes Through-the-microscope lens lighting
Glare Change direction and magnitude of light
ring lights located around the bottom
of a microscope lens, provide an ideal
lighting setup. LED ring lights that pro-
vide up to 1,900 foot-candles of light are
available.
Gooseneck ber-optic illuminators
providing up to 40,000 foot-candles of
light provide visibility in any hole. Ring-
lighted 4 magnifying glasses (about
130 foot-candles) are also good choices
for the upper size limit of micro work.
Some applications require bottom
lighting rather than side or top lighting.
Microscopes that incorporate coaxial,
through-the-lens light sources direct the
light right where the eye is looking and
are ideal for small, deep holes.
L. Gillespie
Lab brings metrology,
micromachining R&D
to Lithuania
Altechna Co. Ltd., a Lithuanian laser
technology company founded in 1996,
recently tripled the size of its laboratory
facilities for R&D and metrology. Te
Vilnius-based company, which focuses
on photonics and laser research, manu-
factures diode-pumped laser sources
and components, develops laser micro-
fabrication applications and designs op-
tomechanical assemblies.
Te new metrology lab at Altechnas
R&D division, called Workshop of Pho-
tonics, performs QC on optical com-
ponents and evaluates laser microma-
chining results, according to R&D Sales
Architect Evaldas Pabreza. Half of our
company is devoted to production of
optics, laser crystals and similar things,
so its very important to ensure the qual-
ity of these components, Pabreza said.
Financed by the Lithuanian govern-
ment and the European Union, the new
Workshop of Photonics lab measures
optical surface quality; transmittance
and reectance; surface atness and
wavefront distortion of at and spheri-
cal optics; the angles of prisms, wedges
and other optics; and noncontact radius
of curvature and focal-length measure-
ments, according to Pabreza.
Te facilities also include two labs
equipped with femtosecond lasers and
a laser assembly lab, all with cleanroom
facilities. Te Workshops researchers
work with their counterparts at corpo-
rate and academic partners to develop
new small-scale laser production pro-
cesses. Research partners include the
Laser Research Center at Vilnius Uni-
versity; Lithuanias Panevio Mecha-
tronikos Centras; Swinburne University
of Technology, Melbourne, Australia;
and Japans Laser Systems Inc.
For more information, call +370-5-
2725-738 or visit www.wophotonics.
com.
J. Destefani
Mikron Corp. Monroe
Tel. 203 261 3100
Email: mmo@mikron.com
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MMMMMMMMMMMMMMMMMMMMMMMMMMEEEEEEEEEEEEEEEEEEEEEEEEEEAAAAAAAAAAAAAAAAAAAAAAAAAASSSSSSSSSSSSSSSSSSSSSSSSSSUUUUUUUUUUUUUUUUUUUUUUUUUURRRRRRRRRRRRRRRRRRRRRRRRRREEEEEEEEEEEEEEEEEEEEEEEEEEMMMMMMMMMMMMMMMMMMMMMMMMMMEEEEEEEEEEEEEEEEEEEEEEEEEENNNNNNNNNNNNNNNNNNNNNNNNNNTTTTTTTTTTTTTTTTTTTTTTTTTT matters
S
train gages were invented 70 years ago
and have been used for years in products
such as pressure sensors. Today, the gages
are found in everything from small medical
devices to aircraft components to bridge
structures.
Te electrical resistance of strain gages
changes as the strain, or force, applied to
them varies. Calculating that change provides
the gages measurement capability.
Te main application areas for strain gages
are experimental stress analysis for R&D and
manufacturing transducers for end products.
Transducers, or sensors, include pressure
sensors, load cells (a transducer used to
measure forces) and torque sensors.
Straintensile and compressiveis defor-
mation of material that occurs on the surface
of an object. Conventional strain gages
consist of an insulating exible backing that
supports a metallic-foil grid. Produced by
photoetching a pattern into the foil, the grid
determines the electrical resistance of the
strain gage. Te more gridlines, the higher
the resistance, according to Dirk Eberlein,
product and application manager at HBM
Inc., Marlborough, Mass.
Te foil is bonded (glued) to an insulating
polymer backing material. Tis carrier is
then attached with an adhesive to the surface
of the object under stress. As the object is
stressed, the foil is deformed, causing its
electrical resistance to change. Other gage
components include a coating to protect
against external eects, such as humidity or
mechanical damage, and lead wires.
Most strain gages are smaller than a
postage stamp (9mm 12mm), but they can
be much smaller. Typical strain gages are
6mm 5 mm (for uniaxial strain gages with
a 3mm grid length) or 13mm 6mm (for
uniaxial strain gages with a 6mm grid length).
Uniaxial means the strain is measured in one
direction.
Measured in ohms, resistance is converted
to millivolt output via a Wheatstone bridge (a
divided bridge circuit used to measure elec-
trical resistance). Te strain taking place is
measured by applying a gage factor, which is
the ratio of relative change in electrical resis-
tance to the mechanical strain.
Te information is transferred to a data-
acquisition device. Te data is used for
control and to warn when too much force
is being applied, said Bill Richards, vice
president of sales and marketing at Strain
Measurement Devices Inc., Wallingford,
Conn. For instance, a sensor can be put in
a robotic hand and when the hand touches
something, it tells the controller how hard
that robot hand is touching [the object]or
even if it is touching it.
For stress analysis on larger structures,
hundreds or thousands of tiny gages are
applied. Aircraft manufacturers, for example,
install thousands of strain gages on the body
and wings to measure strain and, from that
measurement, recalculate the mechanical
stress, said Eberlein.
Micro strain gages
Manufacturers oer a variety of strain
gages for micro applications.
HBM, for example, has developed a strain
gage with a foil-grid size of 0.3mm 0.9mm.
Te carrier size of 2mm 1.2 mm also is not
typical for a foil strain gage, said Eberlein.
Our aim was to get 120-ohm performance in
the smallest grid size possible.
Designed for stress analysis, HBMs
micro strain gage can be used in R&D,
When showing strain is a good thing
Three types of standard
strain gages: uniaxial (bottom
right), biaxial (top right) and a
so-called chain with 10 grids
on one carrier (left).
HBM
such as testing mechanical stress inside of electronic parts
directly on a printed circuit board. One of HBMs German
customers installed a micro strain gage on a fully equipped
PCB to determine how handling aected the board after it
was manufactured. Other applications include measuring
strain in notches and bore holes as small as 2mm, as well as
between rivets found on aircraft.
Strain Measurement Devices has used a thin-lm-
vacuum-deposition process to bond strain gages directly to
various metal substrates for 20 years. Tese gages are used in
transducers to measure force.
A thin-lm strain gage eliminates the need for adhesive
bonding to the product being measured. Instead, insulation
is deposited onto the stressed metal surface to insulate the
circuit from the metal substrate, said Richards. Ten, a thin
lm of resistive alloy is sputtered over the dielectric layer in a
vacuum chamber. Te lm is taken out and laser-trimmed to
produce the four resistors of the Wheatstone bridge. Bonding
pads are applied, and wire is bonded to the circuit to provide
a power egress, then the whole thing is coated with an encap-
sulation layer to protect the thin lm.
According to Richards, the lack of adhesive promotes
more intimate contact and long-term stability and better
repeatability than [is found with] foil gages. When you adhe-
sive-bond the foil onto the surface of an object, errors are
introduced. Te more materials you have between the thing
that is actually doing the sensing and the thing that is doing
the moving, the more error you have.
Te thin-lm strain gage has proven itself in applications
where small size is required. Te smallest such gage Strain
Measurement oers is 6.35mm, according to Richards. One
application is in the medical eld. Delivery of uids to the
body via pumps or irrigation systems in implantable medical
devices can be interrupted by a pinched tube or pump failure.
Engineers often use tube sensors to monitor pressure in the
pump system by measuring the force exerted onto a sensor
pressed against the expanding walls of tubing. Or they place
the sensor behind the pump to record pressures as the pump
backs up against the sensor during operation.
Semiconductor strain gages, used mainly for manufac-
turing transducers, operate the same way as metal-foil and
thin-lm gages, but they are not produced the same way.
Tey are made with single-crystal silicon instead of metal foil.
We dont have to etch gridlines in the silicon; it is all
one piece, said Rick Lester, semiconductor lab manager at
Micron Instruments, a Simi Valley, Calif., manufacturer of
semiconductor gages. Te silicon itself is the resist. Ours are
mounted right to the unit, and then they are encapsulated
with a protective coating. We can put them on a carrier, but
when people want something really small they use the indi-
vidual strain gages.
Tese types of gages are well-suited for measuring small
amounts of strain because of their high sensitivity. Te
semiconductor gage has a lot more electrical output than
a metal-foil gage, Lester said. Foil gages have extremely
low output. With semiconductor gages, you can get a much
stronger signal. You have better resolution, so you can check
very minute movement.
Because semiconductor gages have higher resistance than
metal-foil gages, less material is required, which means they
can be smaller. Our smallest is 0.0018" (0.025mm) long, said
Lester. An interesting application involves placing the gage in
a capsule that enters a patients heart to monitor it.
Disadvantages of semiconductor gages are that they are
more sensitive to temperature variations and are more
expensive than metal-foil gages. Also, handling is more di -
cult because they are brittle.
About the author: Susan Woods is a contributing editor to
MICROmanufacturing. E-mail: susanw@jwr.com.
By Susan Woods,
Contributing Editor
T
o satisfy the requirements for micro-
machining applications, spindle
manufacturers continue to develop products
that are faster and more compact, accurate,
powerful and thermally stable.
One area of special interest for spindle
manufacturers is Swiss-style machines. For
example, NSK America Corp. last year intro-
duced the iSpeed3 spindle series for live
tooling on Swiss-style automatic lathes. Te
spindles have an integral electric DC brush-
less motor and an accuracy of less than 1m
TIR, according to the company. Te iSpeed3,
which has a maximum length of 103mm, is
intended as a replacement for a machines
standard spindle, noted Dick Garski, senior
sales manager for the spindle manufacturers
U.S. sales o ce in Schaumburg, Ill.
Te series includes 19.05mm- and
20mm-OD spindles with a variable speed
from 1,000 to 80,000 rpm and 22mm- and
25mm-OD spindles with a variable speed
from 1,000 to 60,000 rpm. Tese spindles
are designed to increase the speed of the
machine, Garski said. Te standard rpm on
most of those Swiss-type machines is 8,000
rpm for live tooling.
Micropart manufacturers desire high
spindle speeds not only to achieve an
adequate chip load but also to boost produc-
tivity when running microscale cutting
tools. Its going to take forever to machine a
reasonable-size surface unless youre running
at very high speeds, said Chris Gerrard, R&D
manager for Westwind Air Bearings.
Te Poole, U.K.-based spindle manufac-
turer oers units with speeds up to 350,000
rpm for drilling 0.004"-dia. and smaller
microholes in printed circuit boards. It also
has supplied spindles for micromachining
metals, such as brass and aluminum, for the
watchmaking industry.
Although Westwind produces air-driven,
or turbine-driven, spindles with speeds up to
100,000 rpm, Gerrard noted that direct-drive
electric motors are the choice when a high-
speed micromachining application requires
real control. He indicated, however, that
turbine spindles are easier to incorporate into
a machine, particularly if an end user is doing
the upgrade.
You dont have to buy a high-speed
inverter to get the electric power into the
spindle, Gerrard said. You just need an air
line and a control valve and away you go. He
added that Westwind sells 95 percent of its
spindles to machine tool builders.
Bill Popoli, president of IBAG North
America, North Haven, Conn., agreed that
spindles with air-driven motors are typically
not powerful enough. IBAG oers its Micro
line of spindles with housing diameters as
small as 16mm for Swiss-style machines.
Te speed range is from 60,000 to 80,000
rpm, and a brushless DC motor delivers the
required power and torque, Popoli noted.
For a lot of small-part applications, partic-
ularly if theyre in medical, youre cutting
stainless steel, so theres a need for higher
torque, he said.
In addition to spindles for Swiss-style
Spindle developments for micromachining
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIICCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRROOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOmachining
IBAG North America
IBAGs Micro line for Swiss-style machines includes
these 22mm- to 25mm-OD spindles.
machines, IBAG is building models
for 3- and 5-axis machining centers
with automatic toolchangers. Te
company has developed a special rotary
coupling to put high-speed spindles on
lathes with turrets, which require elec-
trical or pneumatic connections for the
spindles.
To illustrate the advantage of an elec-
tric spindle compared to a pneumatic
one, Garski recalled how a customer
near Salt Lake City who was using an
NSK air-motor spindle to machine a
hexapod drive on a bone screw reduced
cycle time from 45 to 15 seconds by
switching to an iSpeed3 spindle.
Te most critical requirement
for virtually all markets, including
micromachining, is controlling and
minimizing thermal growth of the
spindle, according to Bill Howard,
product line manager for Makino Inc.,
Mason, Ohio, a machine tool builder
that produces its own spindles. To
achieve that, Makino begins by passing
temperature-controlled lubricant
through the center of the spindle to cool
the core. Te technique relies upon
long passageways and designed orices
to facilitate oil ow, he said, adding that
the patented process attacks heat gener-
ation at its sourcethe spindle core.
Eectively lubricating spindle bear-
ings also keeps thermal growth in
check, but as spindle bearings spin
faster and faster, centrifugal force
prevents lubricant from reaching the
inner bearing race, where it is needed,
Howard explained. Terefore, Makino
provides under-race lubrication to
ensure lubrication and temperature
control. Were lubricating the bearings
from the inner race out, he said.
Makino reports that a third method
to control thermal growth is to add a
cooling jacket that encloses the inte-
gral spindle, which means the armature,
windings and motor are part of the
spindle. Te jacket connects to an
Oilmatic, or chiller, unit that tightly
controls spindle lubrication tempera-
ture, relative to the machines bed. Tis
ensures that the spindle and bed main-
tain a constant, controlled relationship,
providing a temperature-controlled
manufacturing platform, Howard
noted.
Even microns of thermal growth in
the spindle are going to cause issues in
micromachining, he said.
About the author: Alan Richter is senior
editor of MICROmanufacturing. Telephone:
(847) 714-0175. E-mail: alanr@jwr.com.
By Alan Richter,
Senior Editor
End Mi l l Sol ut i ons
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The iSpeed3 series electric-powered
spindles from NSK America provide speeds
up to 80,000 rpm and are for live tooling
on Swiss-style automatic lathes.
Westwind Air Bearings
A 1mm, single-crystal-diamond tool on a
Westwind 160,000-rpm spindle machines
brass samples at Cranfield University.
LLLLLLLLLLLLLLLLLLLLLLLLLLAAAAAAAAAAAAAAAAAAAAAAAAAASSSSSSSSSSSSSSSSSSSSSSSSSSEEEEEEEEEEEEEEEEEEEEEEEEEERRRRRRRRRRRRRRRRRRRRRRRRRRpoints
Gas gives big assist to many lasing jobs
M
any of todays laser processes
are performed with an assist
gas, which is a pressurized stream of
gas directed either coaxially with or
lateral to the laser beam. In cases where
an assist gas isnt required, its often
applied to reduce processing time and
enhance workpiece quality.
Assist gases are used in laser oper-
ations like cutting, drilling, welding,
deposition and surface alteration. A
common application is the production
of stents: coronary, urinary, urethral/
prostatic, colonic, duodenal, vascular
and peripheral vascular. Te stents are
made from biocompatible metals that
are laser-cut in ways that give them
the exibility to be snaked through
the body and su cient rigidity to hold
open the orice into which they are
being inserted. Kerf widths of tens to
hundreds of microns are typical, and
outstanding surface nish is a must
especially for drug-eluting stents.
A typical vascular stent has a wall
thickness of about 0.003" and strut-size
tolerances around 0.0003". Te required
surface nish is about 0.00015" (mirror
nish), or 5 percent of wall thickness.
Such requirements couldnt be met
without an assist gas.
Among the reasons to apply assist
gases are:
To remove molten debris from

the workpiece surface. E cient
removal of slag minimizes post-
process cleaning and helps protect
the lasers lens.
Cool the workpiece.
Inhibit oxidation. Frequently, a

cover gas is applied that blankets
the processing area with an inert
gas. Doing this prevents oxidation
at the high temperatures associated
with laser welding and laser cutting
of metal. (Note: Te process some-
times is performed in an enclosed
environment, like a laser glovebox.)
Enhance oxidation, which speeds

the burn process. Tis is often
done when cutting stainless steel.
Assist gases are teamed with infrared
lasers more often than ultraviolet lasers.
One reason is that, generally, IR lasers
are used to welda common applica-
tionand UV lasers are not. Te short
wavelength and associated short pulse
length of the UV laser do not lend
themselves to joining applications.
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When an assist gas is delivered coaxial with the laser beam, beam centering is critical.
Another reason is that UV spot sizes
are generally much smaller than IR
spot sizes, meaning there is less molten
material for an assist gas to remove
during a UV-laser operation.
Finally, with the exception of excimer
lasers, UV lasers are generally delivered
through galvanometer beam-delivery
systems. Tese do not lend themselves
to coaxial gas processing.
Two UV applications where assist
gas is used are pulsed-laser deposi-
tion and laser cleaning. Tin lms of
HtSs (high-temperature superconduc-
tors) can be deposited uniformly and
rapidly with UV lasers and the appro-
priate gas environment. Other coatings
can be applied by this method as well,
including thin lms of crystalline and
amorphous silicon.
Laser cleaning systems for the semi-
conductor market remove organics
from wafers. One of them, a patented
cleaning technology from UV Tech
System, Sudbury, Mass., utilizes green
gases coupled with laser light to remove
organic materials from the surface of
silicon wafers and other substrates.
Te light and gas reaction creates a
gas reaction zone that photochemi-
cally and/or photo-ablatively removes
selected material from the surface. No
solvents or chemicals are required
only an inert gas like oxygen or
nitrogen.
Te most common assist gas applied
in traditional laser processing is CDA
(clean, dry air). Because the slightest
presence of water will kill many
processes, the air needs to be extremely
clean, dry and pure. Other gases usually
have some purity specication.
An obvious choice to enhance oxida-
tion is pure oxygen. Used for cutting
and drilling certain metals, it generally
is placed in the reactive-gas category.
In order to limit oxidation, such as
when welding metals, an inert cover gas
is used. Tese gases include nitrogen,
helium, neon and argon. A light gas
like He moves quickly and can easily
enter very small spaces. Larger gas
molecules, like Ne and Ar, are heavy
and tend to make better cover gases.
Tey have enough massand therefore
momentumto deect ejected material
from the processing area. Even H
2
and
CO
2
are used on occasion. It has been
shown that gas mixtures sometimes
perform better than pure gases.
Laser cutting and drilling metals
usually create a HAZ (heat-aected
zone) that sometimes must be removed
with a secondary process. Tis is
undesirable and can be minimized or
eliminated by applying the right gas
mixture. Steel, for instance, responds
well to a mixture of O
2
and N
2
. Stain-
less steel and aluminum respond well
to a mixture of N
2
and CDA, while tita-
nium and nickel alloys respond well to
Ar and He.
Welding requires an assist gas to
perform three main functions: protect
the HAZ from oxidation, minimize
plasma eects in the weld area and
expel plasma from the weld joint.
Helium is the gas of choice because of
its high ionizing potential and minimal
metallurgical concerns, but it is expen-
sive. Argon is less expensive, but it has a
lower ionizing potential and the perfor-
mance is not as good as with He. Here
again, a gas blend may be preferable.
By Ronald D. Schaeffer,
PhotoMachining Inc.
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The polyimide sheathed MicroFlex
Flexible is now availble in diam-
eters of 0.5 mm (.020), 0.9 mm
(.035), and 1.5 mm (.059), and
lengths up to one-meter (39.4).
Gas pressure is vital
and can vary greatly.
For micromachining
purposes, 80 psi probably
is suffcient.
LLLLLLLLLLLLLLLLLLLLLLLLLLLAAAAAAAAAAAAAAAAAAAAAAAAAAASSSSSSSSSSSSSSSSSSSSSSSSSSSEEEEEEEEEEEEEEEEEEEEEEEEEEERRRRRRRRRRRRRRRRRRRRRRRRRRRpoints
Gas pressure is vital and can vary greatly. For microma-
chining purposes, 80 psi probably is su cient. Applications
involving larger lasers, though, call for pressures up to 300 psi
and ow rates up to 1,000 standard cu. ft./hr.
Beam centering with a coaxial delivery system is
extremely important, especially when trying to achieve
consistent results in multidirectional cutting. For the
oxygen-assisted cutting of steel, for example, concentricity
should be within 50m. Centering of the gas nozzle is done
after focusing.
When coaxial gas-assist delivery is not possible, external
nozzles can be used to direct the gas at the target area
obliquely. Te direction of the gasi.e., toward, away from
or perpendicular to the direction of travelcan make a big
dierence in on-target quality.
Finally, a key to maintaining excellence in processing over
an extended time period is to consistently apply high-quality
gases. Tis is achieved by partnering with a supplier known
for providing a pure product.
About the author: Ronald D. Schaeffer, Ph.D., is CEO of
PhotoMachining Inc., a high-precision laser job shop and systems
integrator in Pelham, N.H. E-mail: rschaeffer@photomachining.
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DDDDDDDDDDDDDDDDDDDDDDDDDOOOOOOOOOOOOOOOOOOOOOOOOOWWWWWWWWWWWWWWWWWWWWWWWWWNNNNNNNNNNNNNNNNNNNNNNNNNsizing
By Dennis Spaeth,
W
hen Alexander Graham Bell called
Mr. Watson one Friday back in
March 1876, he probably wanted to cele-
brate the invention of the telephone. But
Bells rst phone call should have been to his
team of patent attorneys so they could begin
preparing for the decades-long legal battles
that followed.
Tough this digression into telephone
history may seem o topic, hold the phone.
You see, Bells breakthrough led another
American inventor, Emile Berliner, to come
up with a better telephone transmitteror, as
history would have it, the rst microphone.
Te American Bell Telephone Co. was paying
attention and quickly purchased the rights to
Berliners patent.
Shortly thereafter, Tomas Edison
invented the carbon microphone, which Bell
Telephone would eventually own as well.
Of course, carbon microphone technology,
which was used in phones for the next 100
years or so, didnt escape a patent battle of
its own. Unlike the telephone patent chal-
lenges that continued in one form or another
until 1897, the microphone battle pitting Bell
and Berliner against Edison was resolved in
Edisons favor by 1892.
So much for my childhood memories
of who invented what. Yet if this not-so-
nostalgic trip into microphone history
teaches us anything, it is that many people
contribute to such inventions, and that tech-
nology progresses despite whatever legal
battles may ensue.
Indeed, microphone patent disputes have
managed to span more than a century of
technological advancesfrom the condenser
microphone in 1916 to the electret condenser
microphone (ECM) in 1962 to the MEMS-
based microphones that have evolved over
the past two decades. Today, though, patent
lawsuits surround the microelectromechan-
ical processes involved in producing the
millions of tiny MEMS-based microphones
used in cell phones, smart phones, personal
computers and laptops.
Te legal turf battles are understandable,
given that the market for MEMS microphones
is forecast to grow from just under 700 million
Speaking of small
While microphones still come in all shapes and sizes for a wide variety of applications and needs, they too have done well in the march
toward miniaturization. The Akustica Inc. MEMS microphone shown is 1mm x 1mm x 0.4mm. Silicon die image courtesy Akustica Inc.
DDDDDDDDDDDDDDDDDDDDDDDDDDOOOOOOOOOOOOOOOOOOOOOOOOOOWWWWWWWWWWWWWWWWWWWWWWWWWWNNNNNNNNNNNNNNNNNNNNNNNNNNsizing
units shipped in 2010 to more than 1.7
billion units in 2014, according to iSuppli
Corp., a market research rm based in
El Segundo, Calif. Tats not a particu-
larly surprising forecast considering
smart phones began incorporating two
MEMS microphones in 2010, in a move
to suppress background noise, and are
expected to incorporate even more such
microphones by 2014.
Although noise suppression has
been available since 2006, the arrival
of Motorola Inc.s Droid as well as the
iPhone 4 (from Apple) has caused the
popularity of the technologyand of
MEMS microphonesto soar, iSuppli
observed in a report accompanying its
latest forecast.
Whats more, iSuppli noted that
MEMS microphone makers should
nd it easier to compete with Knowles
Electronics LLC, Itasca, Ill., thanks
to a Nov. 22, 2010, U.S. International
Trade Commission ruling that the
companys silicon microphone patents
were invalid. Knowles, which is cred-
ited with successfully commercializing
MEMS microphones in 2003, remains
the category leader, and accounted for
more than 80 percent of the devices
shipped worldwide in 2010, according
to iSuppli.
While the ITC ruling is sure to be
welcome news for MEMS microphone
competitors such as Analog Devices
Inc., Norwood, Mass., this and similar
legal challenges have done little to
impede the technological progress of
the MEMS microphoneparticularly
where size is concerned.
In fact, from 2003 to 2008 MEMS-
based analog microphones dropped in
size from 4mm 6mm to about 4mm
4mm. Ten in 2008, Akustica Inc.,
a MEMS microphone maker based in
Pittsburgh, rolled out the worlds smallest
MEMS microphone at 2mm 2mm.
Tese dimensions, however, refer to
the overall MEMS microphone package
that must adhere to standard micro-
phone footprints, which shrink more
slowly than the die inside, observed Dr.
Marcie G. Weinstein, marketing strate-
gist at Akustica.
Te size of Akusticas analog micro-
phone die measures just 1mm 1mm
and about 0.4mm thicka feat owing
directly to an acoustic MEMS tech-
nology for which Akustica holds the
exclusive patent rights. Te technology
allows Akustica to fabricate both the
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process and in-house tooling capabilities, we offer complex part geometries with fast lead times and
high repeatability on even the smallest components. When details are critical, choosing a supplier that
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device or to sign-up to receive our case studies visit: www.smcltd.com
Precision at every size
Micro Molding:
Legal challenges have
done little to impede the
technological progress of
the MEMs microphone
particularly where
size is concerned.
continued on page 45

The 6
th
International Conference on
MicroManufacturing ICOMMJ2011

March 7 - 10, 2011
Tokyo, Japan

Held on the campus of Tokyo Denki University in the Kanda district of Tokyo

70 to 80 papers will be presented in technical sessions and
published in the conference proceedings (bound volume & CD).
Theoretical and applied research related to manufacture,
assembly and metrology for components and systems with
micro/meso-scale features will be presented.
Topics

A broad range of processes:

machining
forming
EDM and ECM
Laser-based processes
casting and molding
others;
Applications of current and
emerging micromanufacturing
methods;
The microfactory paradigm;
Micro-scale metrology;
Materials handling and
joining;
Micro-assembly;
Multi-scale modeling and
simulation;
Design for micro manufacturing;
Materials-related issues at the
Mechanics and dynamics of

process behavior at the microscale;
Miniaturization of machines and
equipment:
tooling
fixturing
positioning
motion generation
sensor systems
control;
Contact
Takashi Matsumura, Professor
Tokyo Denki University
Secretary, ICOMM 2011
Phone: +81-3-5280-3391
Fax: +81-3-5280-3568
E-mail:
tmatsumu@cck.dendai.ac.jp

Industry Tour
A post-conference tour will be
organized to RIKEN - The Institute
of Physical and Chemical
Research. RIKEN is Japans
flagship research institution
devoted to basic and applied
research. The tour will visit the
Ohmori Materials Fabrication
Laboratory
Exhibition
A micromanufacturing technology
exhibition will be held during the
conference. Manufacturers of
micromanufacturing equipment, micro-
tooling, metrology and precision devices
will be available to demonstrate and
discuss their products.
Exhibition space is still available.
>
C
ontinued growth in the U.S. market
for implantable medical devices should
translate into both growing opportunities and
challenges for companies that mold and machine
tiny implant parts.
In the U.S., demand for implantable medical
devices is projected to increase by more than 8
percent a yearto almost $50 billion in 2014,
according to Te Freedonia Group, a Cleve-
land-based market research rm. In a report
entitled Implantable Medical Devices to 2014,
Freedonia notes that growth in the implant
market will be spurred by the development of
new devices featuring novel technologies and
better materials. And, ineective drug treat-
ment methods are expected to increase the
use of implantable devices for cardiovascular,
neurological, orthopedic and other conditions,
reports Freedonia.
In the area of so-called active-implantable
medical devices (AIMDs), which are activated
by electricity or some other type of energy,
Freedonia forecasts demand for cardiac implants
to rise more than 7 percent annually, to about
$17 billion in 2014. Key segments of this market
include cardiac resynchronization therapy
devicesthe category expected to experience
the strongest growth among pacing devices
as well as implantable cardioverter debrillators
and cardiac pacemakers.
Among other AIMDs, Freedonia is bullish on
the prospects for implantable stimulators used
to treat neurological conditions. New stimula-
tion devices and applications are expected to
boost demand by nearly 8 percent annually, to
$1.3 billion in 2014.
As for orthopedic implants, Freedonia sees
U.S. demand increasing almost 9 percent annu-
ally, reaching nearly $26 billion in 2014. Among
the markets to experience the highest growth
rates is that for reconstructive joint replace-
ments. Spurring the growth are improved
products and the active lifestyles of an aging
population. Freedonia also expects strong
growth for spinal implants, due in part to the
increase of people with chronic back problems,
and trauma xation implants, such as plating
systems for fractures near joints.
MTD Micro Molding
EDMing a micromold for implant parts.
Implant Nation
Smaller parts, larger markets
Cover Story
By Bill Leventon, Contributing Editor
Freedonia predicts the market for
cardiac stents and stent-related implants
will grow more than 9 percent per year, to
over $7 billion in 2014, due in part to the
introduction of improved drug-eluting
stents, as well as strong demand for prod-
ucts such as endovascular stent-grafts and
stents for treating carotid artery disease.
Te carotid stent market also looks
promising to Venkat Rajan of Frost &
Sullivan, San Antonio, Texas. Overall,
Rajan, who tracks medical device sales
for the market research rm, predicted
only modest growth for U.S. implant
markets, whose combined annual sales
he put at around $31 billion. For the
most part, Id say that the implant markets
in the U.S. are fairly saturated, he said.
There are some segments that have
more opportunity ahead of them than
others, but there arent too many that
have double-digit growth rates.
Like Freedonia, Rajan also sees strong
growth potential for neurostimulation
devices implanted in patients who are
unresponsive to rehabilitation and phar-
maceutical treatments. On the downside,
he believes this market is limited by the
fact that the products, though capable of
enhancing the quality of life, arent life-
saving in nature.
Rajan is also optimistic about trans-
catheter valve technology, which he views
as a signicant new development in the
implant market. Te technology, which
allows replacement of heart valves in a
minimally invasive process, opens up
an at-risk patient population that you
potentially werent able to address before
because you dont have to crack open the
chest, he noted.
Shrinking parts, new materials
Due to demand for ever-less-inva-
sive medical devices, the size of implant
parts grows ever smaller. If we made
something [at a certain size] 3 years ago,
today were probably making it half that
size, said Brian Hrouda, director of sales
and marketing for Norman Noble Inc.,
a contract machining rm in Highland
Heights, Ohio. And we continue to see
that trend moving forward.
To meet the part-size requirements
of medical OEMs, Norman Noble plans
ahead. If a customer tells us, Down the
road, we want this part to be half the size
it is now, well start developing a process
to do that, Hrouda said. And well design
manufacturing machines or equipment to
make what they want.
Other implant trends involve the use
of materials. At present, for example,
Norman Noble is experiencing increased
demand for implant parts made of
Micro Precision
Molding Machines Vertical
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Johnson Matthey
Medical microparts machined by Johnson
Matthey from platimum/iridium alloys, 316
stainless, Nitinol and titanium.
Nitinol, a shape-memory alloy. Hrouda
attributed this to medical OEMs success
with Nitinol implant components, as well
as a better understanding of the material
among product designers and regulators.
For years, Norman Noble has been
laser machining Nitinol tubes to create
stents. Now, however, the company
also can machine Nitinol bar stock with
Swiss-style machines. With its unique
characteristics, Nitinol allows engineers
to design products that cant be made
with standard materials, Hrouda said.
But the problem has always been that if
you couldnt laser-machine the product
because of geometry restrictions, you
couldnt make the product out of Nitinol.
Now, our Swiss capability is opening the
door to things like Nitinol bone screws
and other exciting new products.
Demand is also increasing for implant
parts made of platinum. According to
Hrouda, manufacturing methods are
now available that allow machining plat-
inum parts with dimensions that werent
possible in the past.
For example, his company developed
a process called Noble Ultralight, an
athermal laser machining technique
developed to cut precise features in
both metals and polymers. Since it
doesnt produce a heat-aected zone, the
process can machine smaller holes and
other features in platinum parts than are
possible with heat-generating techniques.
In addition, Hrouda pointed out that
the athermal process eliminates the
need for post-processing steps, such as
cleaning and electropolishing, which can
adversely aect features with microscale
dimensions.
In some cases, platinum is combined
with another material that adds strength
or other properties. For example, a plat-
inum alloy that includes 10 percent
iridium is commonly used to make long-
term implantable parts through which
electrical signals pass, said John Morley,
medical product manager for Johnson
Matthey, a U.K.-based global materials
supplier that also micromachines parts
made of platinum and other metals. Te
parts include active xation leads that
attach pacemakers to the heart. Te leads,
made from a platinum-iridium alloy,
oer both biocompatibility and electrical
conductivity, according to Morley.
Much of Johnson Mattheys medical
business involves platinum-based prod-
ucts. But with the price of platinum
soaringalong with the prices of other
commoditiesmanufacturers are looking
for less-expensive alternatives. Terefore,
Johnson Matthey oers customers the
option of switching from platinum to
alloys based on palladium, which can
oer part-to-part material cost savings of
about 75 percent compared to platinum,
according to Morley. As for mechan-
ical properties, Morley maintained that
the two materials are interchangeable,
though he added that there may be subtle
dierences between the two materials
when used in implants.
With comparable properties and a
much lower price, palladium would seem
to be a good deal for implant manufac-
turers. One drawback, however, is the
fact that palladium is new in the medical
device industry. When you adopt a new
technology in this industry, you have to
answer a lot of questions from the FDA,
Morley said. All these questions have
been answered for platinum, but they
have yet to be answered for palladium.
In addition to using readily available
materials, Hrouda reported that implant
OEMS are working closely with material
suppliers to develop proprietary custom
alloys and polymer formulations that
will allow the OEMS to achieve their
product-design goals. In some cases, he
added, the material is a bigger concern
to the OEM than the part design because
of its impact on part performance.
Processing exotic new implant mate-
rials complicates matters for rms like
Norman Noble, because it has to learn
how to machine them.
Implant Nation continued
Implantable medical device demand ($ millions)
% Annual growth
Item 2004 2009 2014 2019 2004-2009 2009-2014
Implantable medical device demand 19,870 32,860 49,050 70,900 10.6 8.3
Orthopedic implants (total): 10,290 16,900 25,800 38,400 10.4 8.8
Reconstructive joint replacements 4,860 7,160 10,490 15,350 8.1 7.9
Spinal implants 2,270 4,460 7,500 11,800 14.5 11.0
Orthobiologics 1,410 2,740 4,170 6,100 14.2 8.8
Trauma xation implants 1,750 2,540 3,640 5,150 7.7 7.5
Cardiac implants (total): 7,460 12,280 17,600 23,700 10.5 7.5
Pacing devices 4,460 6,730 9,000 11,900 8.6 6.0
Cardiac stents 2,300 4,540 7,100 9,540 14.6 9.4
Structural cardiac implants 700 1,010 1,500 2,260 7.6 8.2
Other implantable medical devices 2,120 3,680 5,650 8,800 11.7 9.0
The Freedonia Group Inc.
Rapidwerks
Polymer bone screws molded by
Rapidwerks.
Materials arent the only complicating
factor when it comes to making implant-
able microparts. For example, Hrouda
noted that some of these parts are so
small that they cant be moved individu-
ally with ngers or tools. Instead, batches
of tiny parts are moved together in an
automated process. Norman Noble can
attach roughly 1,000 parts to xtures the
size of a penny, which are then moved
using proprietary automation technology.
Complications can arise during
machining as well. Johnson Matthey, for
instance, has found that a single machine
often cant do everything required to
make very complex and/or high-quality
microparts for implants, according
to Morley. Terefore, the company is
performing more secondary operations
once an initial machining process is
completed.
To make parts for the vasculature
system, for example, the rm starts with
Swiss-style machining and then turns to
EDMing to create very small, burr-free
holes in the parts that allow the passage
of uid inside the body.
Another two-machine process is
used to make tiny electrodes for the
neurostimulation devices that attach to
the spinal cord. First, Johnson Matthey
uses proprietary technology to cut
match-head-size electrode bodies from
tubes made of electrically conductive
precious metals. Ten, the rm switches
to EDMing to cut lengthwise slits in the
tubes. An EDM puts essentially no force
on these very ne parts, so youre not
deforming them when youre cutting the
slits, Morley explained.
Machined to molded parts
Despite such efforts to satisf y
customers, machining may be falling
out of favor with some implant manu-
facturers. For a number of implant types,
there has been a fairly large transi-
tion from machined to molded parts,
according to Scott Herbert, president
of Rapidwerks Inc., a Pleasanton, Calif.,
molder of microparts.
It was once thought to be impos-
sible to mold the tiny features on some
Screw machines
for making
microparts at a
Johnson Matthey
manufacturing plant
in San Diego. The
plant also uses wire
and sinker EDMs,
and lasers for
cutting and welding.
Johnson Matthey
of these parts, Herbert said. But now
that we have the ability to mold them,
companies that typically machined both
metals and plastics are leaning toward
molding the same materials. In the case
of spine cages, machining costs might
be $170 versus less than $10 to mold the
same part, with no secondary machining,
deburring or cleaning required after the
molding process, he noted.
Herbert also maintained that molding
can give implant part designers more ex-
ibility than machining, allowing designs
with complex geometries to be manu-
factured. In some cases, you may not
be able to machine a specic geometry,
but you may be able to mold it and create
something thats more benecial to the
application, he said.
As for materials, Herbert sees another
transition, this one from metals to plas-
tics. For example, he said that implant
manufacturers are looking to replace tita-
nium with polymer materials that are less
expensive but oer similar performance
properties.
One such material is PEEK (polyether
ether ketone), which oers high structural
strength. PEEK isnt an exact match for
titanium in terms of structural strength,
Herbert noted, but for a polymer-based
material, its pretty darn good.
MTD Micro Molding of Charlton,
Mass., which specializes in molding
microparts, is working with an implantable
PEEK grade thats carbon-ber-reinforced
for higher strength. Tis material is suit-
able for applications such as bone anchors
that are subjected to high loads, said
Dennis Tully, president of MTD.
On the downside, such highly engi-
neered materials can be difficult to
process. For example, Herbert noted
that molding the materials can require
temperatures in excess of 750F, higher
than those commonly encountered by
most injection molders.
PEEK is also a costly material, so
molders must keep their runner-to-part
weight ratios much lower than those
used in common molding operations.
Herbert said an appropriate ratio for
molding PEEK might be 6:1, as opposed
to the 60:1 ratio that might be used in
ordinary molding jobs. When youre
molding materials that cost a few thou-
sand dollars a kilogram, molding a runner
[that outweighs the part by] 60:1 is a very
expensive proposition, he added.
Despite its high cost, PEEK may be
specied for implants because its already
well-documented for medical applica-
tions, saving users a lot of trouble in
qualifying their materials. Tus, they
havent arrived at that material from a
properties standpoint; theyve arrived at
it from a convenience standpoint, said
Tully, adding that specifying PEEK when
a less-expensive material like polypro-
pylene would do the job is not necessarily
a great approach in the long term.
As for other material trends, Tully
reported that MTD customers have
recently become interested in TPE
(thermoplastic elastomer) and TPU
(thermoplastic polyurethane) for neuro-
stimulation devices. Te impulse-carrying
parts involved must be exible enough to
allow their passage through the body,
which Tully believes is the reason for the
Implant Nation continued
MOLDED PARTS USED IN IMPLANTABLE
medical devices that come into contact
with human tissue must meet stringent
quality standards. Meeting those
standards starts in the design process
and continues through manufacturing and
packaging.
One key design consideration is
minimizing parting-line height, according
to Brent Hahn, senior sales engineer for
Ankeny, Iowa-based Accumold, which
specializes in molding parts down to the
size of a grain of sand.
The alignment of parting lines must
be extremely precise, because if they are
not you can create ash, he said. The
larger the gap between the mold halves,
the greater the chance of creating a sharp
edge that can break off when the part
is used. And even if doesnt, that sharp
edge might damage human tissue.
While parting lines will always remain
on a part, where those lines are placed is
critical. There will always be a least two
halves creating a 360 parting line, and if
you add slides, inserts or other features,
there will be more, he said.
There may be grooves or other
features in the part that must not have
parting lines, but the molding process
may also dictate the location of parting
lines, so an ongoing dialog between the
molder and the medical OEM during
design is crucial.
During the molding process itself, a
cleanroom is required that meets at least
Class 100,000 standards. A greaseless
mold is also preferred to eliminate
possible contamination from oil, grease
and mold-release agents.
Also, resins used for medical parts
must be protected from degradation
during processing. Medical OEMs choose
resins with specic properties, but those
properties can be degraded when using
equipment with excessive residence
times, said Hahn.
This has long been a challenge for
Considerations when designing and molding medical parts
Accumold
(515) 964-5741
www.accu-mold.com
The Freedonia Group
(440) 684-9600
www.freedoniagroup.com
Frost & Sullivan
(877) 463-7678
www.frost.com
Johnson Matthey Inc.
(800) 442-1405
www.mathey.com
Makuta Technics Inc.
(317) 642-0001
www.makuta.com
MTD Micro Molding
(508) 248-0111
www.mtdmicromolding.com
Norman Noble Inc.
(800) 474-4322
www.normannoble.com
Rapidwerks Inc.
(925) 417-0124
www.micromolding.com
Contributors
material choice.
Polymers are also being developed that
will allow devices to safely reside in the
body for long periods of time, according
to Stu Kaplan, president of Makuta
Technics Inc., a micromolding rm in
Shelbyville, Ind. Were learning so much
more about these kinds of materials than
we knew a few years ago, said Kaplan,
whose company is currently working
with the materials on an experimental
basis. Many of the developments are
condential, he added, but not only is
it happening, its being commercialized.
Still, many medical OEMs remain
unaware of what can be done by leading
micromolders, suggested MTDs Tully.
We have a lot of conversations that
start with someone saying something
like, I know this design isnt going to
be possible, but we had to start some-
where and I wanted you to look at it,
Tully said. But many times we look at
it and say, Tis is nowhere near impos-
sible. In fact, its not all that di cult by
todays standards.
About the author:
Bill Leventon is a New
Jersey-based freelance
writer. He has a M.S.
in Engineering from
the University of
Pennsylvania and a B.S
in Engineering from
Temple University. Telephone: (609) 926-
6447. E-mail: wleventon@verizon.net.
Editors Note: Copies of the report
Implantable Medical Devices to 2014
can be purchased at The Freedonia Group
Web site: www.freedoniagroup.com. For
more information, go to the Medical and
Pharmaceutical Products page.
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molders, he explained. Because of the
small shot sizes used when molding these
microparts, the heated resin can remain
in the machines screw and barrel well
beyond recommended residence times.
That can break down the chemical
structure of the resin; you are literally
baking the desired properties out of it,
he said. If youre molding a bookmark,
it doesnt really matter, but if the part is
going into the body, thats a problem.
Machinery designed for micromolding
can target this problem. For example,
Accumold has devised micromolding
machines that have much shorter
residence times than the industry
standard, according to Hahn.
After the part is molded, it should be
removed from the mold via an end-of-
arm robotic tool and be placed in a clean
bag or tray. No debris from the gate or
contaminants from the mold or press
should fall on the parts.
While some molded parts are placed
in electrostatic-free, high-density
polyethylene bags, Hahn recommended
standard HDPE bags. Some electrostatic
bag makers use soap or corn starch to
reduce static, and these additives can
contaminate parts [used] for implantable
medical devices, he said.
Alan Rooks
S
ome shops view making microparts on a
Swiss-style machine as a dark art, but the
process is just a dierent style of machining
and not something mysterious. Success in this
micro realm requires a blend of special tactics,
attention to detail and top-quality tools and
equipment.
To machine microparts consistently and
e ciently, a CNC Swiss-style automatic lathe
is often the best choice. Te machines can
routinely turn diameters down to 0.003" or
smaller, machine features as small as 0.0003"
and achieve 0.0002" tolerances. A Swiss-style
machine is distinguished from other lathes by a
sliding headstock that feeds a rotating workpiece
through a guide bushing. Typical bar diameters
are from 2mm to 38mm.
A Swiss-style machine offers a range of
machining advantages and capabilities. Static
and rotating side- and end-mounted tools
cut within millimeters of the guide bushing,
eectively eliminating overhang and part deec-
tion. Multiple axes and driven tools enable
nonturning operations, such as milling, drilling
and deburring. CNC technology permits use of
standard tool geometries to produce complex
and nonround shapes. Twin-spindle congura-
tions facilitate nishing of both ends of a part. In
sum, the machines can produce small, precise
parts complete in one chucking.
Segmentation, materials
A machining tactic matched to Swiss-
style machining involves segmentation of the
workpiece. In segmentation, the workpiece is
machined to completion one section at a time.
Te bar is extended a short distance from the
guide bushing, turned to size and then subjected
to operations such as grooving or cross-hole
drilling. When the rst section is completed,
another segment of workpiece is advanced
through the guide bushing, turned, machined
to create other features and so on.
The segment being machined is closely
supported by the guide bushing, but operations
such as peck drilling and single-point threading
Swiss-Style Success
Tools, tactics and tips for productive Swiss-style micromachining
By Glen Crews, Marubeni-Citizen Cincom, and Bill Kennedy, Contributing Editor
B. Kennedy
require that the work be pulled a short
distance back into the guide bushing
(see illustration on page 30). To main-
tain guide bushing support, the pull-back
distance is limited to the stroke of the
machine, usually about
5
8", depending on
the conguration of the guide bushing.
Te bar or wire workpiece fed through
the guide bushing must be large enough
in diameter so it doesnt bend or twist
during feeding, but also be as close as
possible to the nished diameter of the
parts largest OD.
Te smallest bar many shops work
with is
1
16" in diameter. Most smaller-
capacity machines (16mm in diameter
and below) handle
1
16"-dia. material with
minimal di culty.
To consistently achieve such small-
scale precision, it is essential to have a
workpiece material that is metallurgi-
cally and dimensionally consistent. From
a metallurgical point of view, some mate-
rials are easier to machine than others.
For example, brass and copper alloys
generally machine easily. On the other
hand, stainless steel can be more di cult
to machinebut not all grades. Within
300-series stainless steels, the 303 alloy
is not a problem to machine, while the
304 alloy can be very di cult. Bar stock
suppliers have developed premium-grade
alloys to provide optimal machinability
and produce them under tight metal-
lurgical specifications to ensure that
machinability remains consistent from
bar to bar.
Regarding dimensional consistency,
bar stock for micromachining in a
Swiss-style machine typically is center-
less-ground to a diametric tolerance of
0.0002".
More important than absolute toler-
ances, however, is a consistent bar
Guide
bushing
Sliding headstock
Spindle collet
Workpiece
Swiss-style machining basics
Live
tool
Endworking
tool
Turning
tool
Bar
feed
B. Kennedy
In a Swiss-style lathe, a sliding headstock feeds rotating stock through a guide bushing,
eliminating overhang and deflection.
diameter along its entire length. A bar
may be 0.0005" undersize, but as long as
the entire bar is undersize by the same
amount, adjustments can be made to
produce the part dimensions required. In
general, a Swiss-style machine can hold
60 percent of bar stock tolerance; that is,
if bar stock varies by 0.001", the part can
vary by as much as 0.0006".
Additionally, bar stock should be as
straight as possible, exhibiting a bow of
less than 0.001" per 12" of length, and be
round. If the material is out of round, the
machined part will be too.
Tat highlights one disadvantage of
Swiss-style machining: an out-of-round
bar can be chucked between centers in
a conventional lathe and turned round,
but in a Swiss-style machine, an out-of-
round bar will be turning oblong in the
guide bushing, and the machined part will
be the same shape.
Bushing guidance
The configuration, adjustment
and quality of the guide bushing are
major factors in successful Swiss-style
machining. Problems with dimensional
control or tolerances are often the result
of an inaccurate or worn guide bushing.
Tere are two guide bushing styles. For
parts with wider tolerances (greater than
0.0005"), the bushing rotates in sync
with the workpiece material. But tighter
tolerances require a xed guide bushing,
which remains static while the bar stock
spins. A xed guide bushing is adjust-
able and must be sized so that the bar
stock is in full contact with the bushing
but can still spin freely without seizing.
Hand skills and feel for the relationship
between the bar and bushing play a role.
For micromachining, high-precision
guide bushings, which cost more than
standard-quality ones, are needed to
maintain micron-scale tolerances. A
good Swiss-style machine will provide
unvarying repeatability, but if the bar
stock or workholding or toolholding
components are inconsistent, it doesnt
matter how accurately the machine can
repeat.
Tooling is one of the most important
elements of the micromachining process
on Swiss-style lathes. Using tooling engi-
neered specically for micromachining is
crucial. Until recently, it was di cult to
nd insert tools for Swiss-style machines
suitable for micromachining. Te tool-
nose radii were not sharp enough, and
the tools lacked sufficient clearance
angles behind the cutting edge. Fortu-
nately, an increasing number of cutting
tool manufacturers have realized there is
a signicant market for tools engineered
for micromachining, and they now oer
them.
In general, turning tools for Swiss-
style machines have sharp edges, 0 nose
radii and higher clearance angles behind
the cutting edge. It should be recog-
nized that the nose radius of a Swiss
turning tool is not like that of an 80
or 55 diamond-shaped tool. Tools for
Swiss-style machines feature a nearly at,
90angle of contact with the workpiece.
Te atness of the edge acts like a wiper
tool to smooth the work surface.
Te tools also have to be sharp. Te
slightly radiused edge of a typical ANSI-
standard insert requires more cutting
force and, therefore, more machine
tool horsepower. And considering the
extremely light DOC that is characteristic
of many Swiss operations, a sharp edge
is necessary to ensure the insert actually
cuts the workpiece material instead of
simply pushing it.
Swiss-style tools operate in close
proximity to the workpiece, and su -
cient clearance behind the cutting
edge prevents rubbing on the work.
Chipbreakers should be groundnot
moldedinto the cutting edge to ensure
they cut and bend the chip eectively.
Finding drills
Te accuracy of Swiss-style machines
make it possible to drill holes to a
0.0002" or tighter tolerance. But just
as with turning, holemaking presents
specic challenges.
Tere are a limited number of suppliers
that make microdrills. As a result, many
shops apply drills meant for other appli-
cations, such as drilling printed circuit
boards.
A recurring problem with holemaking
on this scale is that manufacturing engi-
neers often design parts with hole
dimensions that dont match standard
WHEN MACHINING MICROPARTS ON
a Swiss-style machine, programming
generally is not as large an issue as
tooling. By their nature, microparts do not
feature overly complex geometries. There
are some truly complicated parts that
cant be programmed manually, but there
are many others that can be programmed
at the machine or ofine.
For complex parts, there are Swiss-
specic automated CAM systems
available, but they can be expensive. A
shop should decide whether that level of
sophistication is necessary for the parts it
makes.
If a shop does decide to employ an
automated CAM system, it should make
sure the programmer learns how to
use all its capabilities. The programmer
should also know how to program a part
manually, so he will be familiar with the
codes being generated and have a sense
of their appropriateness. A CAM system
can generate codes that may not be
Swiss-style Success continued
A key Swiss-style
machining tactic is
segmentation, in which
the workpiece is closely
supported by the guide
bushing and machined to
completion one section at
a time.
Swiss-style programming
G. Crews
letter- and wire-size drill dimensions.
Some cutting tool manufacturers
provide drills down to 0.100mm in diam-
eter, in 0.010mm-dia. increments, but
specials may still be needed for certain
applications.
Regarding special or odd hole sizes, as
well as specic part tolerances, it can be
benecial for a shop to work with part
designers and conrm that the specied
hole sizes and tolerances do have func-
tional value. Reference dimensions can
replace unnecessarily tight tolerances
that can make a part a candidate for
failure in inspection, although it is func-
tionally perfect. Swiss-style machines are
capable of controlling a process beyond
what many quality managers or statisti-
cians say is possible.
When tight hole tolerances are
required, reamers traditionally have
been applied to achieve them. Microscale
reamers, however, are hard to nd. But
even if appropriately sized reamers are
available, it can be di cult to determine
the reamer tolerance that will produce
the nal hole size desired.
As an example, reamers were unavail-
able for one holemaking application
that had a 0.0003" tolerance. Te solu-
tion was custom-made, tight-tolerance
drills engineered to achieve the tolerance
without reaming. After trial and error
determined the exact drill size required,
thousands of parts were successfully
produced.
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suited for what a shop wants to do, but
once the codes are produced, a skilled
programmer can change them to t a
specic application.
A shop also needs to adjust
recommended cutting parameters
found in speed-and-feed charts to t
the requirements of a specic job. The
recommended parameters are not always
achievable because standard machines
often cant generate the high surface
speeds required for very small parts and
tools. In turning, for example, reaching
the recommended surface speed
for a very small part may require a
spindle speed of 25,000 to 30,000
rpm, a speed generally not available
on standard machines. In some cases,
however, a machine can be upgraded.
A machine builder can provide certain
modications that boost effective
machining speeds, including spindle
liners and reduction sleeves for the
pickoff spindle.
Compromises often are necessary
and, in many cases, are quite effective.
Tool geometries play an important role
in nessing machining parameters.
For example, sharper geometries work
better at slower surface speeds. It will
come down to testing and experience;
when a part is machined, the results can
be documented and a cause analysis
performed to nd what is causing the
result.
G. Crews, B. Kennedy
Another issue is part nishing. For
example, burrs that are insignicant on
large parts can cause major problems on
microparts. In many cases, the burr is
bigger than the feature being machined.
Tere are a variety of ways to minimize
formation of burrs or remove them.
For some holes, running the drill
through the hole more than once limits
burr formation. Or, after a cross-hole is
drilled, a pass with a turning tool across
the hole mouth can eliminate burrs.
Another alternative is to drill the hole in
two steps, rst performing a predrill close
to nish size, then nish drilling the hole
to the nal diameter. Te second pass
takes out minimal material and leaves
no burrs.
Cross-holes and other features can be
deburred with nylon wheels or brushes
engineered for use with hand-held tools.
Applied in a live spindle in a Swiss-style
machine, the brush will knock the burr o
without scratching the part. Some shops
adapt tiny dental burs to remove heavier
burrs or make their own deburring tools.
Inevitably, some features are practi-
cally impossible to deburr. In some cases,
the burr just ops back and forth and
never breaks away. Tis is common with
titanium and some stainless steels. As a
result, many shops EDM holes, especially
those manufacturing medical parts that
must be burr-free. Te additional process
consumes more time and
makes the part more expen-
sive, but it is mandated by
the requirement for burr-
free parts.
In many cases, thermal, elec-
trolytic or chemical deburring
is effective, but problems
arise when the burr is bigger
than a part feature or the
part itself. A corner radius
on a small medical part may be
0.005". Burning o the burr removes
metal and can eradicate features
or even blow up the whole part. In
addition, when the amount of metal
involved is so small, the process can
be hard to control.
Capturing and measuring
In addition to nding ways to handle
the actual machining of microparts, an
additional challenge is capturing the
tiny components
after machining and
measuring them.
Te standard collec-
tion baskets of screw
machines are generally too
big for microparts. Ejected
from the subspindle, a part
can oat away or drop through
the mesh in the bottom of the
basket. Machine tool builders
offer a variety of part-handling
systems. One method uses a vacuum
extractor that sucks in the part as the
subspindle releases it.
Generating tiny features is one thing;
conrming their dimensions is another.
On-machine measurement generally
is not available, and post-machining
measurement usually involves noncon-
tact vision or shadowgraph techniques.
It is important to qualify the measuring
system, as well as the people who are
doing the measuring, to ensure measure-
ment is consistently performed.
No Mystery
Te true keys to success in microma-
chining with Swiss-style automatic lathes
are patience and a real desire to make
small parts. It is surprising how many
shops simply dont want to deal with
anything under " in diameter.
It is essential to work carefully because
the dimensions and tolerances involved
leave very little margin for error. On
paper, the part may appear to pose no
problems, but the challenges become
obvious when part details cant be seen
with the naked eye.
Machining microparts on a Swiss-style
machine can be tedious, and it doesnt
always work the same way twice. Tere
is a need to monitor and control every
facet of the process, from the workpiece
material and workholding/toolholding
components to the cutting parameters
and machine tool thermal stability.
Tis type of machining usually comes
down to trial, error and experience.
Builders of Swiss-style machines and
tooling representatives can supply a great
deal of practical information. Its their job
to demystify the process and help shops
facilitate the production of microscale
parts.
About the authors:
Glen Crews is Western
regional sales manager
for Marubeni-Citizen
Cincom Inc., Allendale,
N.J. He is based in the
companys ofce in
Fountain Valley, Calif.
Telephone: (714)
434-6224. E-mail:
gcrews@mcc-h-b.
com. Bill Kennedy is a
contributing editor to
MICROmanufacturing.
Telephone: (724) 537-
6182. E-mail: billk@jwr.
com.
Swiss-style Success continued
Marubeni Citizen-Cincom
This titanium screw for a medical
application, produced on a Marubeni
Citizen-Cincom R07 VI machine, typifies the
continually shrinking scale of parts produced
on Swiss-style machines. The 0.200"-long
part has a 0.015"-dia. shank and features a
0.05"-dia. head with a 0.03"-dia. bore and
four 0.02"-wide 0.03"-deep slots.
Genevieve Swiss Industries
To be fully effective, tools for machining
microscale parts on Swiss-type machines
must be designed for that purpose.
These boring bars are designed to handle
minimum diameters from 0.480" to 0.027".
Live spindles located perpendicular to
the round bar stock enable Swiss-style
CNC lathes to produce small square-
sided parts like this titanium dental
bridge.
B
.

K
e
n
n
e
d
y
A
dding a submersible rotary axis to a wire
EDM, where a chuck mounted on a rotary
table holds the workpiece rather than clamping
it to the machines worktable, serves several
purposes. These are particularly useful for
producing microparts.
EDMingunlike grinding, turning or
millingis a noncontact process and there-
fore doesnt exert side pressure on delicate part
features, including those with diameters of
0.002" and smaller. Tat enables, for example,
production of long, skinny parts.
You would have a very hard time milling a
shape with a 200:1 aspect ratio simply because
the forces tend to deect the part, said Marcus
Carius, a former dentist and owner of Implant
Mechanix, a Vancouver, British Columbia, job
shop that focuses on design, development and
prototyping of dental devices. You dont have
that with wire.
Index, turn and spin
Index and burn, also known as turn and
burn, is the basic function a rotary EDM axis
performs. Te EDM operator pushes the start
button and the rotary table moves the workpiece
to a specic location. When the table stops, the
EDM head cuts the required feature while the
part is stationary before being indexed to the
next location for further cutting, explained Peter
Knowles, president of Hirschmann Engineering
USA Inc., Schaumburg, Ill., a manufacturer of
EDM rotary and tilting tables and other EDM
products.
A more sophisticated method is having the
rotary axis interface with the control so the spark
generator drives the rotary motionturn while
burn, noted Larry Wetmore, western region
sales representative for EDM Network Inc., a
Sugar Grove, Ill., EDM distributor and rebuilder.
Tat enables the table to rotate simultaneously
with any other axis motion in a coordinated
manner and allows the control to monitor the
servo speed and rotary positioning and set the
metal-removal parameters.
An EDM is not like a mill, where you just give
it a feed rate and it shoves the cutter through the
material at that rate, Wetmore said. With an
EDM, both sinker and wire, the control is always
monitoring the cutting action and adjusting
the servos and the spark based on each cut.
For example, an EDM control might slow the
wire, or even reverse its direction, if the wire
approaches a short-out situation.
When the rotary axis external control inter-
faces with a wire EDM via an M codewherein
it handshakes with the machine, allowing
it to run automaticallyit is also referred to
as an A- or B-axis, Knowles noted. Having a
rotary axis integrate directly with the machine
control eliminates the external control and
enables synchronous motion. In this case, if
you can turn while burn, you can index and
burn, he said.
When integrating a rotary axis into a wire
EDM, its important that the unit has a low
prole so the machines upper and lower heads
can be positioned as close as possible to the
workpiece. Tis is necessary to achieve the tight
tolerances typically specied for micro parts
and features, explained Gisbert Ledvon, busi-
ness development manager for EDM builder
GF AgieCharmilles, Lincolnshire, Ill.
Ledvon noted that the smallest wire it oers
for turn-while-burn applications is 0.0008"
Rotary Burn
A rotary axis turns a wire EDM into a lathe
By Alan Richter, Senior Editor
GF AgieCharmilles
In rotary EDMing, the table can rotate in coordinated motion with other axes for
simultaneous 5-axis cutting. In this case, the part is rotated during the cut.
(20m) in diameter. Tat limits how small
the part or feature can be. If your part is
only 20 microns in diameter, you will have
a problem, he said. Te spark energy is
too big, and the part will be destroyed or
break o.
GF AgieCharmilles equips its wire
machines for rotary EDMing with
JauchSchmider micro-erosion spindles,
which have a maximum rotation of 3,000
rpm and a maximum radial runout of
0.002mm. If a customer decides not to
buy it at the beginning, we can always
integrate it later on, Ledvon said, noting
that once integrated into an EDM the
spindle typically stays with the machine,
unless it needs to be removed to accom-
modate a larger part.
In contrast, a stand-alone rotary table
with an external control can be posi-
tioned anywhere on a wire EDMs table
and moved to any machine required,
stated Ann Mazakas, manager of
technical communications for CAM
software developer DP Technology Corp.,
Camarillo, Calif., in her white paper titled
Non-Traditional Wire EDM in Modern
Manufacturing. Automatic sequencing
with the machine tool program can be
achieved through an interface cable,
usually via an M code. To move the table
and control to any other machine requires
each machine to have a connector for the
interface cable.
A third rotary EDM function is high-
speed spinning, where the workpiece
spins around the rotary axis while the
wire cuts a 2-axis prole. Tis is also
known as EDM turning, or spin and
burn.
With EDM turning, you want to make
sure the wire is held vertical and rigid
while the workpiece spins, Mazakas said
during a telephone interview.
She noted that because the workpiece
material for EDM turning applications is
often expensive, the initial rough cut, a
series of indexing moves, should remove
the largest piece of material possible.
It drops to the bottom of the tank and
can easily be recovered later and recy-
cled, Mazakas said. After the rst cut,
the EDM indexes the workpiece to the
opposite side and another large chunk of
material is cut.
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Rotary Burn continued
GF AgieCharmilles
A GF AgieCharmilles Cut 1000 OilTech wire EDM with a JauchSchmider 30319 micro-
erosion spindle for the B-axis was used to apply a 20m-dia. wire to produce an instrument
for performing eye surgery (inset).
The 1.6mm-dia. and 7.9mm-long Nitinol surgical
pin on the left has a coarse finish compared to
the one on the right, which was indexed 48 times
and burned with a roughing and two skim passes
per index. The deviation from cylindricity is under
0.002mm for the pin with the fine finish, but the
processing time was unacceptably long and not
needed for part functionality, according to Implant
Mechanix.
Implant Mechanix
Finish-EDM-turning resembles a lathe contouring operation
where small amounts of material are removed, except no tool
pressure is applied to the workpiece, Mazakas noted.
Spin-and-burn tables do not need to interface with the EDMs
control or provide cutting-condition feedback, according to
Carius. He added that spin-and-burn tables oer the lowest
cost and simplest-to-install option for spinning a workpiece
in a wire EDM. With spin and burn, coordinating positioning
moves between the rotary spindle and the other axes isnt
normally possible. For a spin-and-burn application where
youre pretending your wire EDM is a lathe, typically you need
a high spindle speed, but you dont need to slave the rotary axis
to the discharge generator, he said. In other words, you run
the spindle independently, so its a dumb spindle.
However, a recent development is an integrated all-in-one
A-axis that can index and burn, turn while burn, and spin and
burn. Up until this past year, the problem was that none of
the machine controls could handle all three in one unit, said
Hirschmanns Knowles. He added that not all EDM builders
currently provide that capability, but more OEMs are consid-
ering adapting this capability because they realize theyve got
competitors who can do this and they cant.
Software, other considerations
Eective rotary EDMing requires CAM software developed
for the task at hand. In her white paper, Mazakas recommends
selecting software that can:
Enter machine data about the rotary table.
Provide specialized machining functionality for a wire

EDM with a rotary axis.
Simplify programming through machining features that

include data specic to EDM parts, such as lead-in/lead-out
points, thread points and plane orientation for positioning
moves.
Reliably simulate rotary EDMing.
Enable reliable NC output.

DP Technology, for example, oers its ESPRIT CAM soft-
ware with functionality for rotary EDMing integrated into the
package, Mazakas noted. Its not a separate module, she said,
noting that its suitable for stand-alone and integrated rotary
tables. When you dene your machine in the software, you
just dene a rotary axis.
Careful consideration is also needed when selecting the
equipment for rotary EDMing. Te deionized water a rotary
table is submerged in promotes corrosion, so the unit must be
completely sealed, EDM Networks Wetmore said. He added
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Implant Mechanix
Implant Mechanix developed this experimental surgical bur for
conducting scientific research on rodents and rotary-EDMed it out
of 440C stainless steel with a hardness of 56 HRC. The objective
was to find a cutter geometry that could ream bone with the most
control of cutting depth and final osteotomy without overheating
the bone. The reduced shank permits copious saline irrigation to
help cool the bone during surgery.
Hirschmann Engineering
The Hirschmann H100ABR.NC 2-axis tilting and dividing table is for
EDMing complex part geometries. The B-axis has a 100mm-dia.
faceplate with holes for mounting fixtures.
that a tables design must prevent current
from owing through its specialized bear-
ings and other critical components to
prevent them from eroding.
Keeping radial runout to a minimum
is also a key factor, especially because
its paramount that the rotary axis spin
at 1,500 rpm, or faster, when manufac-
turing round parts, according to Knowles.
Radial runout for most of our units is
better than 0.000080", he said.
Of course, the EDM itself must provide
the required capabilities for the rotary
task at hand, but that doesnt necessarily
mean investing in the latest, greatest
and probably priciestmachine. For
instance, Implant Mechanix purchased
a used 1996 Sodick A320D EDM from
EDM Network to turn-while-burn dental
implant components, prototypes and
low-volume parts as small as 0.5mm in
diameter. Carius noted that his clinical
background helps him engineer and
manufacture dental products for the
gadget-oriented profession. Dentists love
to invent, he said.
That inventiveness assists him in
exploiting his rotary EDMs capabilities.
Te rotary axis makes the machine for
me, because I do so much toolroom work
and relatively little production work,
Carius said, adding that a typical example MachineTools.com
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Rotary Burn continued
Contributors
DP Technology Corp.
(805) 388-6000
www.dptechnology.com
EDM Network Inc.
(888) 289-3367
www.edmnetwork.com
GF AgieCharmilles
(800) CTC-1EDM
www.gfac.com/us
Hirschmann Engineering USA Inc.
(847) 468-9700
www.hirschmannusa.com
Implant Mechanix
(604) 899-8977
www.implant-mechanix.com
is a small run of Nitinol pins for a surgical
screwdriver.
Unlike spin and burn, Carius noted
that the rotation speed on a turn-while-
burn unit may be as slow as 1 rpm, or
slower, to permit the generator setting
to precisely advance the wire along its
instructed path and interpolate the axis to
the movement of the axis to cut a specic
spiral pitch, if desired.
According to EDM Networks
Wetmore, Carius EDM didnt have
turn-while-burn capability when new,
but its design allowed modification
of the control to drive an additional
simultaneous cutting axis. During the
refurbishment process, because I did
that sale myself, I knew Marcus needed a
W-axis on that machine, and we were able
to provide it and modify the control so it
could drive the W-axis, Wetmore said.
For his particular niche, a rotary EDM
enables Carius to create the little stu
with weird and complex geometries that
require lots of indexing, but the tech-
nology often doesnt make economic
sense for a typical job shop because idle
time would be too great without a specic
need. Its expensive as hell, he said.
Youre going to drop $28,000, $30,000
on a rotary axis. For $30,000, you can put
a turning center on your oor that will
outproduce a rotary axis on a wire EDM
by orders of magnitude.
Carius added that wire EDMs are
maintenance-intensive because of the
corrosive work-zone environment.
Everything rusts, rots and falls apart, he
said. Its part of the territory. In addition,
high consumable costsincluding the
wire, deionizing resin and components
that wear and require regular replace-
mentmust be considered. It sets a
barrier to entry, for sure.
Nonetheless, rotary EDMs are capable
of some phenomenal things you cant get
from any other technology, Carius said.
Of course, the usefulness of the machine
depends on your creativity.
DP Technologys Mazakas concurred:
Imagination is the biggest limitation
on the parts that can be cut with a
rotary EDM. Te combination of part
rotation and movement of the wire
during the burn supports part geometry
that often cannot be created in any other
manner.
About the author:
Alan Richter is
senior editor of
MICROmanufacturing.
Telephone: (847) 714-
0175. E-mail: alanr@jwr.
com.
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High-speed EDM turning is ideal for cutting small, dynamically balanced parts because no
cutting forces are involved. Notches, flats, helical grooves and tiny slots can be easily cut in
the same setup.
E
lectrostatic spinning can be used to create a
wide array of micro- and nano-sized bers.
And because the process, patented in 1902 and
usually called electrospinning, is straightfor-
ward, its a relatively inexpensive way to produce
bers.
Tere are at least 16 variations of electros-
pinning performed today, with more expected
to come online as the technology evolves. Te
most common is solution electrospinning.
It involves applying a su ciently high-voltage
charge (15,000v to 25,000v and up to 60kv for
some applications) to a polymer or composite
solution-lled syringe (or capillary tube). A
pump pushes the solution through the syringe
tip at a steady rate, directing the stream toward
a collector plate that has an opposing charge. As
the liquid falls in a circular motion, a solvent in
the solution evaporates, leaving a charged, solid
ber on the collector.
Conventional ber-spinning processes, which
involve extruding a thick, viscous liquid through
holes in a plate, cannot produce usable bers
smaller than 2m in diameter. Te electrospin-
ning process, conversely, can produce robust
bers from 10nm to 10m in diameter. While
typically used for the production of polymer
bers, electrospinning can also produce metal,
ceramic and glass bers, or combinations of those
materials. Te process has been used to make
bers from more than 100 dierent materials.
Electrospinning can be used to produce
solid bers or tubes. In certain applications, the
product is a mesh-like tube or a combination of
materials. Liquids and gases also can be encap-
sulated in the middle of a ber, and gradient
structures can be produced that have properties
that vary along the length of the ber or across
Spinning Tale
Electrospinning: mature technology being used in new ways
By Dr. LaRoux K. Gillespie
RTI International
Inovenso
TO SWISS OR NOT TO SWISS.
Introducing the TRAUB TNL18. an advanced sliding
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of stock to 20mm with and without a guide bushing.
Most machining across
Swiss machines these
days doesnt need a Swiss
machine. But it does need
a fast, productive, precision
turning machine.
So Traub offers a surpris-
ingly affordable solution
with the versatility to
changeover between a
Swiss machine and a
production turning machine
within minutes. The TNL18 is two machines in one.
Simultaneous machining with up to three tools, large
work area with generous axis travels, a huge pool of
fixed and driven tools using double and triple toolholders,
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Its no longer a question.
BOOTH 102
the thickness of nished mats made from the bers.
Raw-material costs span a broad range. Stefano Linari, CEO
of Linari Biomedical, Valpiana, Italy, a manufacturer of biomed-
ical products and electrospinning devices, noted that polymers
range from a few cents per kilogram for gelatin to $43,000/kg
for solutions of gold or rare-earth materials. Platinum is used
for some battery applications.
Many electrospun bers can be coated by CVD (chemical
vapor deposition) or other process to enhance their properties.
Some bers have been coated with silver, which kills disease-
causing germs, molds and about 650 types of bacteria.
Electrostatic-spun bers have application in the ltration,
textile, photonics, medical, energy and aerospace industries.
Fiber characteristics
Electrospinning is well-suited to micromanufacturing. One
reason is the bers molecules or crystals are often oriented
such that they have high tensile strength. Some boast a Youngs
modulus of 50 GPa or higher. (For comparison purposes, 303Se
stainless steel has a Youngs modulus of 19.3).
Because of their cylindrical structure and controllable
porosity, electrospun bers can have surface-area-to-volume
(or mass) ratios up to 100,000 times higher than convention-
ally spun bers.
Te surface-area-to-volume ratio for a cylinder is expressed
as: (2rl) / (r
2
l) = 2 / r
where r is radius and l is length.
So, for a 1"-long, 1"-dia. cylindrical rod, the ratio is 2. For a
1"-long, 0.010"-dia. ber, the ratio is 200. An electrospun ber
of 30nm will have an exposed surface-area-to-volume ratio that
is 100,000 times that of a conventional 0.003" ber.
Fiber diameter can be increased by concentrating the solution
and be decreased by reducing the electrical conductivity of the
solutiontypically by varying salt content. Reducing viscosity
and lowering ow rates also reduce ber diameter.
Porous bers are produced by adding solvents to the solu-
tion that cause phase separation or by producing them in a
high-humidity environment, which creates water islands in
Spinning Tale continued
Syringe
High-voltage power supply
V
Collector
Electried jet
Metallic needle
Polymer or composite
solution
Schematic of electrospinning process details.
the mixture that evaporate as the bers
cool. Salts with small ionic radii produce
ne bers, while those with larger radii
produce coarse bers. Solvent volatility
greatly aects ber porosity.
Fibers can be laid parallel to each
other by using parallel collector plates.
Precise ber placement is made possible
by spacing the plates a few millimeters
apart instead of the typical 10cm to 20cm.
Process variables include solu-
tion viscosity; polymer concentration;
conductivity of the solution, polymer
and solvents; solution surface tension;
polymer molecular weight; and volatility
of solvents used (i.e., vapor pressure).
Other factors inuence process results,
too, including electrical eld strength;
ow rate; distance from nozzle tip to
the collector; tip design and placement;
collector design; take-up velocity on the
collector plate; temperature; humidity;
and atmospheric pressure.
Co-electrospinning
Metals, glasses and ceramics can
be added to bers via a process called
co-electrospinning, reported Dr.
Joachim H. Wendor and his colleagues
at the University of Marburg (Germany).
With co-electrospinning, different
ELECTROSTATIC SPINNING MACHINES,
like the bers they produce, are available
in a wide range of models.
A single-nozzle electrospinning
machine like those typically used in a
laboratory sells for $17,000 to $60,000,
according to Abdulah Aslamaci of
NanoFMG. Machines able to electrospin
bers can be easily constructed from
simple lab supplies for much less,
assuming a high-voltage power source is
available. Equipment for mass-producing
electrospun bers costs from $170,000 to
$300,000.
Elmarco USA makes both prototyping
and production-capable electrospinning
systems. The companys organic ber
production line can make 80nm- to
700nm-dia. bers at speeds of 0.2m/
min. to 5m/min. Setup times range from
5 to 20 minutes. Machine maintenance
takes about 15 hours per month for
systems with four spinning electrodes.
Elmarcos fastest machines, which spin
400nm-dia. PVA bers (producing lters
with a ber density of 0.1 g/m
2
), can
produce 11 million square meters of such
products annually from a single machine.
The companys machines for inorganic
materialssuch as TiO
2
, Li
4
Ti
5
O
12
, Al
2
O
3
,
SiO
2
, ZrO
2
and other oxidescan produce
300nm bers at a rate of 1,370g/hr.
using six heads.
Linari Biomedical builds desktop
electrospinning machines for R&D
applications. The companys EasySpin
model, which uses a single syringe at
40kv, sells for $4,900. For higher-volume
production, the unit can be equipped
with 15 syringes and a 120w generator
operating at 60kv.
L. Gillespie
Sampling of available electrospinning machines
Someone challenged us
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Inovenso
Abdullah Aslamaci
materials are pumped through two coax-
ially arranged chambers. Te process
allows spinning of hollow bers and bers
having a core and a shell.
To incorporate these nonpolymer
materials into fibers, low-molar-mass
precursor materials, such as metal salts,
must be added to the outer polymer.
Subsequent treatment of the precursor
removes it. (Tis can be achieved by chem-
ical means, evaporation or sintering.)
Several layers of materials can be
deposited, allowing the creation of
complex bers. Te outer shell could
be designed to change over time, for
example, or to modify itself as the envi-
ronment its used in changes.
Because multiple materials can be
encapsulated, electrospun fibers can
also incorporate nanoparticles, including
ferromagnetic or superparamagnetic
particles. Use of these particles permits
manipulation of bers by an external
magnetic eld. And because the magnetic
eld can be turned on and o, handling
of microsized components is simplied.
As mentioned earlier, one property
of micro- and nano-bers is that their
surface-to-volume ratio is high. Tis can
greatly enhance their ability to absorb ions
in capacitor applications and allow them
to produce powerful miniature capaci-
tors. Carbon nanotubes have already
been made into miniature eld-eect
transistors that, compared to semicon-
ductor-based devices, exhibit a 20-fold
improvement in transconductance. Te
high electrical conductivity of carbon
nanobers (490 siemens/meter) opens
up many potential electrical applications.
For comparison purposes, the electrical
conductivity of Nylon 6 is 110
-15
s/m
while annealed copper is 5.810
7
s/m.
Nanober applications
Among the current applications for
nanobers are ltration and separation
devices and medical products for treating
wounds, said Stanislav Petrik, strategy
and business development director for
Elmarco USA, a Morrisville, N.C., manu-
facturer of prototype and production
electrospinning machines.
Elmarcos vice president, Fred Librand,
added that electrospun bers also are
used to remove bacteria and viruses
during the manufacture of common
drugs, such as Tylenol, as well as high-
end heart medicines. The superfine
bers ensure that molecules of unwanted,
dangerous life forms do not pass through
the solutions into the nal product.
Other sources noted that fabrics made
from electrospun bers are commercially
available and that electrospinning is key
to certain medical applications, including
the production of biomaterial scaolds
used in human-tissue engineering and
drug-delivery systems.
Two potential areas of application for
electrospun bers are polymer batteries
and fuel cells. Polymer batteries already
power some notebook computers and
cell phones. Lithium-ion cells built with
PVDF (polyvinylidene fluoride) have
better wettability and thermal stability
than existing battery materials.
According to Librand, anything that
shrinks the distance between a batterys
electrodes improves performance and
reduces its size. Nanobers conform to
the smaller is better mindset of todays
designers.
Speaking of electrodes, because poly-
mers can be converted to carbon rods, it
may be possible to electrospin 20nm elec-
trodes for EDMing operations.
As for other developments, it seems
a good bet that even smaller bers than
the 20nm-dia. ones available today will
be oered commercially. TiO
2
, MgO and
Common polymers Inorganics Others
From solution From melt
Cellulose acetate (CA) Polypropylene (PP) TiO
2
Antibiotics
Nylon 6.6 (PA 6.6) Polyethylene (PE) Li
4
Ti
5
O
12
MgO
Polyurethane (PU) Thermoplastic
Polyurethane (TPU)
Al
2
O
3
Lignin
(wood cellulose)
Polyacrylonitrile (PAN) Nylon 12 (PA12) SiO
2
Lignin with platinum
Polyvinyl alcohol (PVA) ZrO
2
Boron nitride
Nylon 6 (PA6) Other ceramics Co/PVA
Polyamide Ti/PVA
Polyvinylidene uoride
(PVDF)
Zn/PVA
Polyethylene Oxide
(PEO)
Poly caprolactone
(PCL)
Ti/PCL
Hydroxyapatite
(Hap/PCL)
Polypeptide
Polyaniline
Polyaramid (Kevlar)
Polysiloxane liquid
crystal (LCPC)
Protein
Collagen
Teon AF
L. Gillespie
Table 1: Fiber materials produced via electrospinning.
R. Rangkupan and D.H. Reneker
SEM image of electrospun polypropylene
fiber 300nm in diameter wrapped around a
very fine textile fiber.
DDDDDDDDDDDDDDDDDDDDDDDDOOOOOOOOOOOOOOOOOOOOOOOOWWWWWWWWWWWWWWWWWWWWWWWWNNNNNNNNNNNNNNNNNNNNNNNNsizing
transducer and electronics in a single
chip using standard complementary-
metal-oxide-semiconductor (CMOS)
processes.
In short, Akusticas die is very
tiny because it is just the [moving]
membrane and the circuitry on a
single chip, as opposed to one chip for
the microphone and a second for the
circuitry, said Weinstein.
In the future, she continued, I see
the size of the MEMS microphone,
from an overall package point of view,
as getting even smaller. Te largest part
of the chipset in an analog microphone
is the analog portion, she noted.
Tough Akusticas digital-output
MEMS microphone package has a foot-
print of 3.76mm 4.72mm, that has
more to do with the industry standard
than necessity. Inside the digital-output
microphone is a die that is 1mm
1mm 0.4mm. Using the same CMOS
MEMS technology, Akustica integrates
an acoustic transducer, an analog ampli-
er and a modulator on a single chip.
Ultimately, we believe that the
industry will drive toward microphones
that approach the size of the chip itself,
Weinstein suggested. With our single-
chip technology, well be in the optimal
position to address this market.
Tough it will take some time, Wein-
stein also forecast a day when digital
MEMS microphones outnumber
analog devices in consumer electronics.
For the moment, digital MEMS micro-
phones are mostly conned to the
laptop computer market.
Computer makers wanted to move
the analog microphones away from the
motherboard and into the screen area
of laptops. Radio-frequency interfer-
ence, however, would have wreaked
havoc with analog signal traces, which
meant they would have had to be
shielded, and that would have made
them too large to t through the hinge
of the laptop.
Te digital-output MEMS micro-
phone, on the other hand, isnt
susceptible to RF interference, noted
Weinstein, so that solved a huge
problem for laptop makers, which
began incorporating digital MEMS
microphones in 2006. And the fact
that two digital MEMS microphones
can share the same trace was good
news for laptop makers, which are now
incorporating multiple digital MEMS
microphones for even better voice
quality communication.
Whether analog or digital, the future
of MEMS microphones sounds pretty
good.
About the author: Dennis
Spaeth is electronic media editor for
MICROmanufacturing and Cutting Tool
Engineering. Telephone: (847) 714-0176.
E-mail: dspaeth@jwr.com.
continued from page 20
Al
2
O
3
bers as small as 5nm in diameter
have reportedly been made in the labo-
ratory, but not mass-produced.
Mass-production is currently limited to
producing bers with diameters of about
50nm, in most materials, said Abdullah
Aslamaci of Nano Fiber Membranes
Group (NanoFMG), Istanbul, Turkey.
Eorts are also afoot to overcome the
biggest drawback to electrospinning nano-
bers: low production rates. (Syringes can
deliver material only so quickly!)
According to Linari of Linari Biomed-
ical, increasing production from each
machine will require:
Using machines with multiple

syringes.
Applying multijet, needle-less

devices, although this technology
lacks repeatability for nonwovens
because the jet formations are essen-
tially random.
Developing a new approach to

obtain very high spatial control of
each single jet, so as to be able to
write with the nanowire during
its production at several millimeter/
second, with submillimeter resolu-
tion. With this capability, a single
head with hundreds of holes can be
used to maintain quality.
Increasing the flow rate of the

extruder/pump system with an
advanced, high-voltage system that
increases charge transfer to the
polymer.
Dr. Seeram Ramakrishna, vice presi-
dent of research strategy at the National
University of Singapore, noted that
close cooperation among scientists in
research institutes, universities and
companies will be required to overcome
electrospinning production problems.
Given the risky nature of adopting
new technologies, companies can tap into
the experience and expertise of scien-
tists and electrospinning research labs to
reduce the risk and overhead. Centers for
such collaboration can be found around
the world.
About the author: Dr.
LaRoux K. Gillespie is a
retired manufacturing
engineer and quality
control manager. He
is the author of 10
books on deburring
and more than 200
technical reports and articles on precision
machining. E-mail: laroux1@earthlink.net.
Contributors
Abdullah Aslamaci
NanoFMG
www.nanofmg.com
aslamaci@nanofmg.com
Elmarco USA
(919) 334-6495
www.elmarco.com
Linari Biomedical
www.linaribiomedical.com
info@linarisrl.com
Prof. Seeram Ramakrishna
National University of Singapore
dprsr@nus.edu.sg

Dr. Joachim H. Wendorff
University of Marburg (Germany)
wendorff@staff.uni-marburg.de
PPPPPPPPPPPPPPPPPPPPPPPPPPPRRRRRRRRRRRRRRRRRRRRRRRRRRROOOOOOOOOOOOOOOOOOOOOOOOOOODDDDDDDDDDDDDDDDDDDDDDDDDDDUUUUUUUUUUUUUUUUUUUUUUUUUUUCCCCCCCCCCCCCCCCCCCCCCCCCCCTTTTTTTTTTTTTTTTTTTTTTTTTTTSSSSSSSSSSSSSSSSSSSSSSSSSSS/services
AUTOMATIC/PRODUCTION LATHE.
Index/Traub offers the new TNL18
sliding-headstock automatic lathe and its
variant, the TNL18P production machine.
The TNL18 can be changed over in
minutes to perform production turning of
long or short parts, with or without a guide
bush. Traub, a subsidiary of the Index
Group, recommends the machine for
producing medical components and claims
it offers precision and qualified surface
finish in a single operation. Fast turret
indexing provides a chip-to-chip time of
0.3 seconds. Simultaneous machining with
multiple tools ensures high productivity
levels by both machines. Up to three
tools can be used simultaneously on two
spindles.
(317) 770-6300
www.index-werke.de
PHOTO-ETCHING FABRICATION
SERVICES. Vacco Industries designs
and manufactures photo-etched
components for the aerospace, defense,
medical, electronic, filtration and
automotive industries. Components
include microfluidic devices, screens
and meshes, fuel valves, manifolds,
electronic components and disc filters.
Vacco fabricates parts from aluminum,
brass, copper, nickel alloys, polyimides,
carbon and spring steels, stainless steels
and titanium. The company can process
materials from 0.0003" to 0.125" thick.
Other services include diffusion bonding,
precision photo-electroforming, adhesive
bonding and laser micromachining.
(626) 443-7121
www.vacco-etch.com
TABLETOP WELDERS. Welding-equipment
manufacturer Miyachi Unitek Corp.
introduces a series of tabletop soldering
systems for reflow soldering, heat-seal
and ACF bonding, hot-bar bonding and
heat-staking applications. The bonders
are for assembling devices such as PCBs,
medical devices, cellular phones, onboard
computers and cockpit instrumentation.
The units incorporate pneumatic bonding
heads that feature the companys Thermo-
Plane thermodes, which reportedly offer
ultrafast heating and cooling cycles,
maintain co-planarity and withstand
deformation.
(626) 303-5676
www.miyachiunitek.com
MICROMOLDING SERVICES. SMC
Ltd. is a contract manufacturer for the
medical industry. Capabilities include
micromolding, silicone molding, injection
molding, secondary operations, packaging
and sterilization of finished devices. SMC
can produce complex micromolded parts
0.003 cu. in. and smaller while holding
tight tolerances. Automation capabilities
range from complex fixtures to fully
automated assembly and packaging
lines. Product design and development
capabilities include industrial design,
mechanical design, FEA, electrical
engineering, software development,
prototyping and product testing.
(715) 247-3500
www.smcltd.com
ROTARY BROACH TOOLHOLDER.
Polygon Solutions Inc.s rotary broach
toolholder has new features, such as
sealed bearings that require no routine
maintenance, an adjustment-free design
requiring minimal set-up time and a
pressure-relief hole allowing fluid and air
to escape. The holder accepts industry-
standard 0.500"-dia. 1.75"-long rotary
broaches. It has a compact design that
reduces the tooling envelope for tight
machining operations, including screw
machines. Broaching standard-size hex
and square forms is possible due to
the toolholders high-quality bearings,
according to the company.
(239) 628-4800
www.polygonsolutions.com
WIRE EDMS. Fanucs RoboCut iE wire
EDM series is available from Methods
Machine Tools Inc. The machines are for
processing difficult-to-machine materials,
such as cobalt-chrome, high-nickel
alloys and titanium. They are capable of
geometric accuracy tighter than 0.0001"
and produce virtually no recast, according
to the company. The machines feature
Fanucs upgraded Ai Pulse Control II, which
minimizes the witness line at the wire
approach and step point, and improves
oval-shape and small-round-hole accuracy.
(978) 443-5388
www.methodsmachine.com

to the transistor, could MEMS ever
conform to a standardized process ow.
So what now?
Just because MEMS cannot conform
to the IC model does not mean we
should abandon the quest for standard-
ization. MEMS devices do need to be
made cheaper and faster in order to
enter additional markets. But we need
to look elsewhere for a transformative
manufacturing business model.
As a mechanical engineer who once
shepherded parts through a machine
shop and now does custom MEMS
development for dozens of dierent
applications, I believe the MEMS
industrydespite its use of silicon
wafershas far more in common with
producers of custom-machined parts. A
machine shop, like a MEMS fab, uses a
suite of machines, such as mills, lathes,
saws and benders, to perform specic
functions. Te same shop might make
products as diverse as door hinges or
engine blocks. No two mechanical
products will move through the shop
the same way because their widely
varying featuresthe very features
that make them door hinges or engine
blocksdemand dierent manufac-
turing steps. Sound familiar?
MEMS manufacturing is microma-
chining. We use plasma and silicon like
a shop uses drill bits and workpiece
materials. To reduce manufacturing
costs and product development time,
we should be looking to machine shops
for ideas and emulating their manufac-
turing models.
In a shop, one nds standardiza-
tion not in the process ow, but in the
tools and methods that accompany
each machine tool, such as drill bits,
saw blades, cutting speeds, sheet metal
gages and fastener sizes. Mechanical
engineers have learned to work within
these machine-specic standards
when designing products. Tey specify
3.0mm holes, for example, instead of
3.023mm holes because the former can
be drilled with a standard tool, which
makes the part cheaper to produce.
To improve our manufacturing e -
ciency and lower costs, the MEMS
industry must start thinking about how
to standardize at the tool and/or recipe
level, similar to how a standardized set
of drill bits accompanies the drill press.
Standardization of MEMS silicon wafer
specications such as for layer thick-
nesses of silicon-on-insulator devices,
silicon-etch recipes to achieve specic
depths or aspect ratios, and commonly
used lm deposition thicknesses are all
within easy reach.
Te potential benets are many:
standard material specs would

enable material suppliers to plan
production and inventory more
eectively;
standardized tool recipes would

allow foundries to avoid costly
process development and operate
more e ciently; and
MEMS designers could select from

known process modules to ensure
design success and repeatability.
Customization would still be avail-
ablebut, like a machine shop, the
supplied product would be priced
accordingly.
About the author: Dr. Alissa M.
Fitzgerald is founder and managing
member of A.M. Fitzgerald & Associates, a
MEMS product development rm located
in Burlingame, Calif. Phone: 650-347-
MEMS. E-Mail: info@amtzgerald.com.
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAASSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTword
continued from page 48
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAADDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDindex
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ADVERTISER NAME PAGE # CONTACT NAME CONTACT PHONE CONTACT E-MAIL / WEB SITE
Accumold 5 Aaron Johnson 515-964-5741 ajohnson@accu-mold.com / www.accu-mold.com
Advanced Tool Inc. 15 Customer Service 800-345-0210 ext.110 sales@advancedtool.com / www.advancedtool.com
Aerotech Inc. 27 Stephen M. McLane 412-967-6854 smclane@aerotech.com / www.aerotech.com
ALBA Enterprises Inc. 23 Tony Brusca 909-941-0600 tony@albaent.com / www.albaent.com
Arch Micro Tool 25 Dan Wells 877-335-7519 info@archmicrotool.com / www.archmicrotool.com
Cimatron Technologies 18 Lisa Sterling 248-596-9700 lsterling@cimatrontech.com / www.cimatrontech.com
FineLine Prototyping 43 Rob Connelly 919-781-7702 rob@finelineprototyping.com / www.finelineprototyping.com
Genevieve Swiss Industries Inc. 29 Scott Laprade 413-562-4800 slaprade@genswiss.com / www.genswiss.com
Gradient Lens Corporation 16 Doug Kindred 800-536-0790 info@gradientlens.com / www.gradientlens.com
Gradient Lens Corporation 17 Doug Kindred 800-536-0790 info@gradientlens.com / www.gradientlens.com
Harvey Tool Co. LLC Cover 4 Peter P. Jenkins 800-645-5609 pjenkins@harveytool.com / www.harveytool.com
IBAG North America 18 Rick Testani 203-407-0397 sales@ibagna.com / www.ibagna.com
ICOMM 2011 21 Takashi Matsumura 81-3-5280-3391 tmatsumu@cck.dendai.ac.jp / www.icomm.northwestern.edu
INDEX TRAUB 39 Jeff Reinert 317-770-6300 info@indextraub / www.indextraub.com
Indo-MIM Cover 3 Jag Holla 609-651-8238 infous@indo-mim.com / www.indo-mim.com
MachineTools.com Inc. 36 785-965-2659 info@machinetools.com / www.machinetools.com
Makino Inc. 3 Mark Rentschler 800-552-3288 mark.rentschler@makino.com / www.makino.com
Marubeni Citizen-Cincom Inc. Cover 2 Diane Brooks 201-818-0100 dbrooks@mctz.com / www.marucit.com
Metrigraphics Precision Components 40 Fred Pitman 978-658-6100 fpitman@drc.com / www.metrigraphicsllc.com
Microcut 34 Joe Dennehy 781-582-8090 info@microcutusa.com / www.microcutusa.com
Mikron Corp. Monroe 11 Hans Liechti 203-261-3100 hans.liechti@mikron.com / www.mikron.com/tool-us
The Mill-Rose Co. 29 Paul Miller Jr. 800-321-3533 info@millrose.com / www.millrose.com
Monster Tool Co. 13 Josh Lynberg 888-CARBIDE sales@monstertool.com / www.monstertool.com
Monster Tool Co. 35 Josh Lynberg 888-CARBIDE sales@monstertool.com / www.monstertool.com
NSK America Corp. 36 Vickie Prescott 800-585-4675 vickie@nskamericacorp.com / www.nskamericacorp.com
Polygon Solutions Inc. 23 Steve Durbin 239-628-4800 steve@polygonsolutions.com / www.polygonsolutions.com
Rollomatic Inc. 31 Eric Schwarzenbach 866-713-6398 solutions@rollomaticusa.com / www.rollomaticusa.com
SmalTec International 9 Jerry Mraz 630-364-1788 www.smaltec.com
SMC Ltd. 20 Business Development 715-247-3500 inquiry@smcltd.com / www.smcltd.com
Streamliner & Associates 37 Rolf Kraemer 814-440-1548 streamliner@coaxpa.com / www.streamlinertools.com
Titan Tool Supply Co. Inc. 9 Frank Menza 716-873-9907 info@titantoolsupply.com / www.titantoolsupply.com
Tungsten Toolworks 10 John Forrest 800-564-5832 john@toolalliance.com / www.tungstentoolworks.com
LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAASSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTword
MEMS makers: machinists who work in silicon
By Dr. Alissa Fitzgerald,
A.M. Fitzgerald & Associates LLC
T
he versatile and amazing silicon devices
that are microelectromechanical systems
(MEMS), such as microphones and iner-
tial, light and pressure sensors, have already
found their way into a multitude of consumer
electronics devices and automobiles, among
other products. As exemplied by the prolif-
eration of iPhone apps that utilize motion
sensing, there seems to be no end to what one
can do with MEMS devices, from the sublime
(lifesaving automotive stability control
systems) to the ridiculous (the iBeer app).
MEMS technology was pioneered nearly
40 years ago by mechanical engineers who
wanted to make tiny 3-D structures out
of siliconnot transistors. Tey used the
tools at hand, borrowed from integrated
circuit (IC) manufacturers, and shaped
silicon with light, chemicals and plasmas
in the cleanroom facilities known as fabs.
Once regarded as exotic, crazy stu, MEMS
has become a mainstream technology with
annual global sales of $8 billion.
Now that bigger markets are at stake,
particularly in consumer electronics, atten-
tion is focused on how to make MEMS
cheaper, faster and better. Te drumbeat
for standardization has started. Te loudest
call is coming from those who believe that
MEMS, being made from silicon wafers,
ought to conform to the successful IC
industry model: process standardization. In
the IC industry, wafers are manufactured
using set process ows with rigid design rules
controlled by the foundries.
Tere is a good reason for the IC system.
Standardized, highly controlled processes
allow foundries to run a few processes very
well and provide their customers with low-
cost, high-yielding chips through economies
of scale.
Tose with an IC perspective often lament
that MEMS manufacturing is stuck in the
trap of one product, one process and is
therefore doomed to high production costs
until it can conform to the IC model. Tis
commonly held belief, however, is borne
from the awed assumption that MEMS
devices are just like ICs. Tey are not.
MEMS devices are mechanical: Tey are
freestanding bridges, diaphragms, hinges and
trusses, shrunk down to microscopic size.
Like any mechanical structure, their features
are intentionally selected to serve a partic-
ular mechanical function, whether deecting
under certain loads or resonating at a speci-
ed frequency. Te height, or Z-axis, of these
features is created by the process steps of
etching (sometimes deeply into the silicon
wafer) or by material deposition. Dierent
MEMS designs must use dierent process
ows because it is not possible to create
two dierent Z-axis features with the same
process.
ICs, on the other hand, are planar devices.
A cross-sectional slice of an IC chip reveals
a Z-axis structure that forms transistors,
the common building block of all integrated
circuitry. An IC designer creates new designs
by linking transistors on the wafers X-Y
plane into dierent circuits. Many IC designs
can be manufactured using the same process,
as long as they share the same basic transistor
architecture.
Te planar nature of ICs facilitates process
standardization. Te IC manufacturing
model consists of the foundries that own the
Z-axis designand therefore the process
owand the chip companies that own the
X-Y axes design, such as the circuit. Only
with a common Z-axis building block, similar
A.M. Fitzgerald & Associates
An example of MEMS machining capabilities:
free-standing silicon cylinders, 12m in diameter,
40m Z-axis height and arrayed on a 40m
pitch, formed by plasma etching into a silicon
wafer.
continued on page 47
Harvey Tool Company, LLC
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Micro Manufacturing Magazine

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Elk Grove Village, IL

New orders rose 0.7 percent in

Shipments climbed 0.8 percent in

Te December 2010 Purchasing

Plant capacity reached 71 percent in the

Manufacturing jobs inched up 1.2

To remove molten debris from

Cool the workpiece.

Inhibit oxidation. Frequently, a

Enhance oxidation, which speeds

Pro MicroFlex Borescopes

A broad range of processes:

Mechanics and dynamics of

series with the VirtualGrind

Pro software suite is the right

Enter machine data about the rotary table.

Provide specialized machining functionality for a wire

Simplify programming through machining features that

Reliably simulate rotary EDMing.

Enable reliable NC output.

Using machines with multiple

Applying multijet, needle-less

Developing a new approach to

Increasing the flow rate of the

standard material specs would

standardized tool recipes would

MEMS designers could select from

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