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Micro Milling

PRECISION MICRO MILLING, MACHINING AND MANUFACTURING COMPANY

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Machining the Impossible – Micro Milling Services

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 very similar in motion to larger 3-Axis CNC milling machines where the cutting tool moves across the X, Y, and Z linear axes, micro-milling machines construction differs by using an extremely stiff frame design, enhanced guideways systems, advanced thermal controls, ultra-responsive servo motors, extremely high speed motorized spindles and world-class industrial CNC controls. These specific differences set micro-milling machines into a complete class of their own which allows them to achieve micron level accuracy, repeatability and surface finishes that no standard CNC milling machine can match. Micromilling machines can produce features smaller so small that high power magnification is required to even see them.

Micro Milling - EDM Department

Micro-Milling Capabilities

Tighter Tolerances equal better finishes when it comes to milling. The 3-Axis CNC Micro Milling equipment used at EDM Intelligent Solutions offers precision micro milling capabilities with tight tolerances as tight as 0.0002″ (2-3µm micron). Constant development of new and improved machining techniques allows us to continuously offer our customers tighter tolerances and better finishes that set us apart from other precision CNC machine shops. Working with our vast network of suppliers, we have access to any tool needed to meet your milling, micro milling or micro manufacturing needs. 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. 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 is also made possible by this network of suppliers. This ensures that our CNC milling machines are never left waiting 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 and Sinker EDM , as well as 3D measurement of machined components for full quality assurance.

 

Micro-Milling Specifics

  • 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) 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

MICRO MILLING MATERIALS

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.

 

Micromilling Compatible Materials

EDM Intelligent Solutions has completed thousands of Micromilling 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 Micromilling Machining and how EDMIS can source that material for you.

  • Aluminum
  • Brass
  • Copper
  • Exotic Metals
  • Molybdenum
  • Titanium
  • Tungsten
  • Tool Steels
  • 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
Rapid Prototyping Materials

MICRO MILLING PROJECTS

For the past 25 years, corporations, laboratories, and universities across the country have been utilizing our milling, micro milling & precision milling capabilities. With such a vast array of electrical discharge machining options to supplement our milling capabilities, we’ve produced thousands of components in a multitude of industries. Research and Development projects needing only one or two pieces are common and through integrated machine automation, the quantities of parts being completed can easily be scaled up to meet the high volumes required by some of our largest customers.

This is just a small sample of all the types of components that EDM Intelligent Solutions has manufactured using our advanced Wire EDM machining processes. There really aren’t many types of parts that EDMIS has not worked on in some form over the last 25 years serving these industries. No project is too big or part too complex or tolerance too tight for EDM Intelligent Solutions which makes us the preferred partner for OEM manufacturers nationwide. To learn more about how EDMIS can help you contact our manufacturing team with your request for quote.

 

Sample Micro Milling Applications

  • Interconnect Components
  • Fiber Optic Components
  • Medical Components
  • Optical Lenses
  • Research & Development
  • Aerospace Industry
  • Defense Industry
  • Digital Manufacturing & Design Innovation Institute (DMDII)
  • Nationally Ranked Universities
  • Research Labs through the country, ex: SLAC national Accelerator Laboratory

Competitive Micro Milling Machining Solutions

Over the past 25 years, we’ve completed thousands of Micro Milling projects. What differentiates EDM Intelligent Solutions manufacturing services from the competition is our ability to not only hold micron tolerances but to do so while still offering globally competitive pricing and lead times. Utilizing our vast knowledge of Micro Milling techniques and decades of industry experience, we are confident that we can produce your most challenging components to your exact specifications. To learn more about how EDMIS can help you contact our manufacturing team with your request for quote.

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