Without proper tooling, one cannot imagine the challenges of entering a world of micro machining where the tooling used is sometimes also very challenging to see.

Today there is a very fast-growing need for micro machining tooling capabilities and it cannot be taken lightly. This is because new methods of medical and dental treatments continuously require new miniature components. These, in many cases, result in much less invasive procedures, enabling patients to recover more easily. High-speed communications advancements also are coming at rapid fire pace by using smaller componentry for less resistance in transmission of signals, sounds, etc. Many of these components also require mating molded parts, which also are extremely small. These molded components require smaller tooling than normal.

Where many drill and mill companies offer standard tooling from ¼: to 1″ or 1¼” diameters, others offer from 6mm (.236″ dia.) down to 0.1mm (.0039”dia) high-tech tooling of solid and coolant through carbides. Tools can also be made available down to .01mm (.00039″) diameters. At this point, you are at the 10 micron level. Considering that a human hair is 60 microns or .0024″ diameter, machining practices become very exact.
With the challenge of overseas competition continually bearing down on North American manufacturers, moldmakers need to provide solutions, tools, and most importantly, availability. Problem solving and proper tooling with availability is key. In short, how moldmakers service the micro moldmaking market is extremely critical.

Presently, a moldmaker has the benefit of being able to machine his components in the semi hard or hardened states, which means that he also can eliminate polishing by using proper tooling—thus not needing to handle the part many times. This is done by selecting the proper starting, finishing and super finishing mills that are available in the above mentioned sizes. Hard drilling also is possible in many cases.

In the past, the components would be finished as best as possible with machining methods, such as tracer mills and/or multi operation-type NC/CNC operations, then polished, heat treated and sent to a plater. These processes could involve weeks or months of handling prior to assembly, testing and shipping.

With the advent of multi-axis machinery and the high-tech tools of which we speak, this has changed. We now have the option of finishing intricate forms in the heat-treated state to a polished finish, then plating, assembling, testing and shipping or using the mold in production. This is how the moldmaker can provide better service to his customer, but the tooling needs to be available to him.

When choosing the tooling, quality, repeatability and availability are the three most important criteria. Purchasing in this manner will be key to producing the results needed for a cost-efficient process. If one shops only for price, there is a great possibility of scrap, delivery delays, etc.