Micro Milling

Our Micro EDM Manufacturing Process

Micro Milling not only supports our electrical discharge machining processes like Wire EDM and Sinker EDM, it is also offered as a stand-alone service to our customers in a wide range of industries. Our 3-Axis CNC mills are capable of cutting with tools smaller than the diameter of a human hair. Advanced thermal controls integrated directly into the structure of our 3-Axis milling machinery ensure consistent cutting performance and production of quality components. Scalable machine tending robotic automation tied to each 3-Axis CNC mill allows for continuous production to run around the clock.

What is Micro Milling?

While larger 3-axis CNC milling machines operate with similar X, Y and Z linear motions, micro milling machines are designed for a fundamentally different level of precision.

These machines feature exceptionally rigid frames, superior guideway systems, advanced thermal regulation, highly responsive servo motors, ultra-high-speed spindles and top-tier industrial CNC controls. These enhancements place micro milling equipment in a distinct category, enabling it to achieve micron-level accuracy, unparalleled repeatability and surface finishes far beyond the capabilities of conventional CNC mills. micro milling can produce features so small that specialized magnification is required to observe them.

The EDMIS Micro Milling Advantage

At EDM Intelligent Solutions (EDMIS), precision is our foundation. For more than 25 years, we’ve specialized in tight-tolerance manufacturing and 3D metrology, helping manufacturers, researchers and engineers across aerospace, medical, defense, automotive and electronics industries push the boundaries of what’s possible in micro-scale production and micro EDM machining.

Our advanced micro milling services deliver the accuracy, repeatability and surface finishes required for today’s most demanding applications. From prototype to production, we combine deep manufacturing expertise with proprietary measurement systems to ensure every part meets the highest standards of quality and performance.

When to Choose Micro Milling Over Other Machining Methods

While electrical discharge machining (EDM), laser ablation and conventional CNC milling each have distinct strengths, micro milling often delivers the ideal combination of accuracy, flexibility and surface quality, especially for components that demand exact geometry and repeatable detail at the micron level. You may choose micro milling in specific applications, such as:

1. When Parts Require Ultra-Fine Detail and Sharp Edges

Micro milling excels at producing small, intricate geometries that traditional milling might struggle to achieve cleanly. For example, medical implants, miniature gears and microfluidic channels often require edge sharpness and surface finishes that cannot tolerate recast layers or heat-affected zones. Micro milling removes material mechanically, maintaining the original material properties and crisp edge definition.

2. When You Need Superior Surface Finish Without Post-Processing

Micro milling can achieve surface finishes as smooth as Ra 0.05 µm, minimizing or eliminating secondary finishing operations. This makes it an ideal choice for optical components, sealing interfaces and medical tools that must be ready for use right off the machine.

3. When Heat Sensitivity or Material Integrity Is a Concern

Since micro milling is a mechanical removal process, it generates minimal heat and maintains the material’s metallurgical structure. This makes it particularly well-suited for heat-sensitive alloys, polymers and composites used in aerospace and electronic applications.

4. When Dimensional Accuracy Must Be Verified During Production

Unlike many traditional machining processes that rely on post-process inspection, EDMIS integrates real-time 3D metrology directly into its micro milling workflow. That means each feature can be verified and adjusted during machining rather than after. This level of precision control ensures consistent accuracy across production batches.

5. When Speed and Efficiency Are Top Priorities

Micro milling’s flexibility and automation capabilities often translate to faster turnaround times. By combining rapid spindle speeds, automatic tool changers and robotic part handling, EDMIS achieves efficient, 24/7 production without compromising quality. For customers balancing tight delivery schedules and complex designs, micro milling can reduce total production time and overall cost compared to slower operations.

6. When You Need Complex Multi-Material or Hybrid Components

For assemblies that use micro milling materials or combine different materials, such as metal-to-ceramic interfaces or conductive inserts within insulating housings, micro milling offers adaptive feed control and fine toolpath programming to ensure that transitions remain accurate and free of mechanical stress, even in difficult-to-machine combinations.

At EDM Intelligent Solutions, we guide every customer through the process of determining the best machining method for their part’s geometry, tolerances and performance goals. Because EDMIS offers a full spectrum of precision machining services, we can recommend the process, or combination of processes, that achieves optimal results for your design.

Capabilities

Ultra-Precise Micro Machining Specifications and Technical Capabilities

In milling, tighter tolerances directly translate to superior surface finishes. At EDM Intelligent Solutions, our 3-axis CNC micro milling machines provide precision capabilities with tolerances as fine as 0.0002″ (2–3 microns). By continually refining our machining methods, we consistently deliver tighter tolerances and smoother finishes, setting our services apart from other precision CNC shops. Leveraging our extensive network of suppliers, we can access virtually any tool required to fulfill your milling, micro milling or micro-manufacturing projects.

In some cases, the tooling used is so small in diameter (as small as 0.0010″) that the cutting end is barely even visible to the naked eye. Our network of suppliers allows us continuous access to and timely delivery of standard and custom micro milling tools made to our exacting requirements from a variety of standard and exotic materials. This ensures that our CNC milling machines are never left waiting for cutting tools to arrive while the milling process is active 24/7.

Extreme machining efficiencies are possible due to the integrated automation that changes both cutting tools and workpieces with no human intervention. This enhances overall productivity and saves our customers’ time and money. Our decades of CNC machining experience and state-of-the-art equipment enable us to provide repeatable quality parts and components from nearly any type of material.

We are continuously working with our technology partners to upgrade our CNC milling capabilities to meet the ever-evolving needs of our diverse base of customers. We also complement our micro milling capabilities with other manufacturing services like Wire EDM, Fine Hole Drilling and Sinker EDM, as well as 3D measurement of machined components for full quality assurance.

EDMIS micro milling systems are engineered to achieve micron-level accuracy on complex geometries and miniaturized components. Below are our standard performance and capability ranges.

Precision Tolerances and Technical Specifications

• Advanced 3-Axis CNC Micro Mills built for efficient 24/7 operation
• Thousands of different sizes and types of micro cutting tools are available, some as small as 0.0010″ (25 microns) in diameter
• Multiple cutter materials and coatings enable selection of the best option to efficiently mill a vast array of workpiece materials
• Workpieces up to 8″ thick are commonly machined
• Precision micro milling tolerances as tight as 0.0002″ (2-3µm micron)
• High-speed micro-drilling of thru and blind holes and hemispheres are easily machined with Micro Milling
• Surface Finishes down to 8Ra µin (micro inch), verified through our Surface Roughness Measurement Test, eliminate finishing and require no additional polishing
• Small quantities of 1-50+ pieces with quick turnarounds
• Contract Manufacturing of full production quantities of thousands of pieces

Advanced Equipment Specifications With Spindle Speeds and Tool Capabilities

Each EDMIS micro milling center features a high-frequency spindle capable of operating at speeds up to 60,000 RPM. These spindles deliver the low runout, dynamic balance and vibration damping essential for micro-scale operations. At these speeds, the tool engages the material with minimal cutting force, preserving both surface integrity and tool life.

The tooling used in EDMIS micro milling operations is as refined as the machines themselves. We employ solid carbide and diamond-coated end mills, supported by tool holders designed to minimize deflection and maximize repeatability.

Quality Assurance Workflow and Measurement Processes

Every EDMIS project starts with a fully integrated workflow built around accuracy, repeatability and traceability. Our micro milling centers and micromachining services feature multi-axis control, thermal stabilization and in-situ metrology, enabling real-time feedback without removing the part from the machine.

Key equipment highlights include:

• High-speed micro milling centers with ultra-precision motion control.
• Temperature-controlled machining environments.
• Tool changers optimized for micro-scale tool holders.
• Integrated 3D surface mapping and automated alignment systems.

Our quality assurance process includes:

1. Pre-machining inspection: 3D metrology defines baseline geometry.
2. In-process monitoring: Continuous tool wear tracking and compensation.
3. Final validation: Non-contact optical and tactile inspection ensures all dimensional and surface criteria are met.

Micro Milling vs. Conventional Machining

While both techniques remove material to shape a part, micro milling operates on a scale that allows for tighter control, finer tooling and more sophisticated measurement.

By combining ultra-fine machining accuracy with advanced automation, EDMIS helps customers:

• Reduce secondary operations by up to 85% through near-net surface finishes.
• Shorten lead times with integrated inspection that eliminates back-and-forth rework.
• Lower production costs with precision that prevents waste and material loss.

EDMIS leverages robotic part handling, automated tool changes and adaptive job scheduling to maintain consistent production without interruption. This lights-out capability supports continuous manufacturing while ensuring traceable quality for every part produced.

Materials

Comprehensive Material Capabilities for Critical Micro Components

Through strategic sourcing partnerships with a vast array of qualified material suppliers nationwide, we can manufacture your components from the exact materials that you require. Strict quality standards are met by all vendors and material suppliers to EDM Intelligent Solutions to ensure that the components we produce can meet the highest standards commonly required by the aerospace, automotive, communications, defense, medical and scientific industries.

EDM Intelligent Solutions has completed thousands of micro milling projects using a diverse set of materials including those listed below. Don’t see your specific material on the list? Contact us to determine if that material can be cut using micro milling machining and how EDMIS can source that material for you.

• Aluminum
• Brass
• Copper
• Exotic Metals
• Molybdenum
• Titanium
• Tungsten
• Tool Steels
  • A-2, A-5, A-6, A-8
  • D-2, D-3, D-5
  • DC-53
  • H-11, H-12, H-13, H-19
  • L-6
  • M-1, M-2, M-3, M-4, M-42
  • O-1, O-6
  • S-1, S-7
  • T-1
• Ceramics
• Graphite
• Plastics
  • PEEK
  • DELRIN
  • NYLON
  • PTFE
  • ULTEM

EDMIS micro milling supports a wide range of high-performance materials, each carefully selected and machined according to its mechanical and thermal properties:

Medical-Grade Materials

• Titanium (Grade 2 & 5): Ideal for implants and surgical components requiring biocompatibility and corrosion resistance.
• Stainless steel (316L, 17-4 PH): Used for surgical tools, dental devices and diagnostic equipment.

Aerospace Materials

• High-temperature alloys (Inconel, Hastelloy): Precision-milled for turbine, propulsion and guidance components.
• Aluminum alloys (6061, 7075): Lightweight structural and avionics parts.

Electronic and Microelectronic Materials

• Copper and conductive alloys: For micro connectors, heat sinks and microchip housing.
• Ceramics and composites: Used in high-frequency or insulating applications.

EDMIS routinely machines hardened tool steels exceeding 60+ HRC, leveraging proprietary cutting parameters and adaptive control software to achieve flawless surface finishes and geometric accuracy. Our proprietary micro milling processes allow us to work with exotic alloys and composites that challenge conventional methods.

Applications

Industry-Specific Micro Manufacturing Solutions

EDMIS combines decades of technical experience with industry-specific insight to deliver reliable, production-ready solutions:

Medical and Pharmaceutical Applications

Our micro milling services support the production of implantable devices, microfluidic components and surgical instrumentation with stringent biocompatibility and traceability requirements.

Aerospace and Defense Applications

From precision nozzles to control housings, EDMIS delivers components that perform under extreme thermal and mechanical stress. Our AS9100 and ITAR certifications ensure compliance with aerospace and defense quality standards, giving customers peace of mind and audit-ready documentation.

Electronics and Microelectronics Applications

We produce miniature conductive components and housings for sensors, communication devices and semiconductor packaging. Our micro milling and metrology integration allow manufacturers to validate microchannel geometries within 2 µm, ensuring reliable performance at scale.

Automotive Precision Components

For next-generation electric and autonomous systems, EDMIS delivers micro-scale components that support high-precision motion control and thermal management. Our work in this space enables suppliers to accelerate product validation and reduce rework cycles by up to 70%.

Scalable Micro Manufacturing: From Prototype to Production

EDMIS offers a flexible, transparent process that scales seamlessly to your requirements. We provide quick-turn prototyping for R&D teams and engineers who need validated proof-of-concept components without compromising accuracy.

Our adaptive manufacturing cells and real-time quality tracking allow production to scale efficiently while maintaining consistent ±0.0002″ accuracy across all parts.

Each project is managed through an autonomous tracking system that records requirements, milestones and inspection data. Customers receive regular updates and detailed reports to ensure full visibility from start to finish.

All components undergo multi-stage inspection and a quality control process, including:

• Surface finish and roughness measurement.
• 3D form verification.
• Statistical process control (SPC) reporting.
• Final dimensional certification.