What are your capabilities in terms of die-sinking EDM for micro-machining?
Our company manufactures its own electrodes up to 5 microns wide and is capable of producing features as small as 12 microns wide. We can confidently state that we have the expertise to produce features 10 times smaller than those of our competitors, particularly as we have developed a new micro-machining process that enables us to create slits up to 1 µm wide. Bear in mind that the diameter of a human hair is 50 µm and that some bacteria are 1 µm in size. To inspect such tiny slits, we use a scanning electron microscope (SEM) which provides a magnification of over 50,000 times.
How many electrodes are needed per room?
Some applications require up to fifty electrodes on a component with a diameter of 1 mm.
We manufacture steam turbine diaphragms; these components resemble a turbine with blades but, unlike turbines, they are static components. To machine the holes in these diaphragms, we have to use 4-axis simultaneous die-sinking EDM. Every day, there are different stages that require multiple electrodes, and this process can continue for a month without interruption.
What level of accuracy can you achieve?
The lowest speeds in electrical discharge machining enable us to achieve gaps of 3 microns and thus achieve precision to within a micron.
Thanks to our new machining process designed for features between 50 and 1 micron in width, we can guarantee accuracies of ± 1 µm.
What are your capabilities in terms of subsidence erosion?
Our machines enable us to machine large parts measuring 500x300x200, as well as parts smaller than 1 mm³.
We are regularly faced with one-off parts that require 4-axis continuous die-sinking EDM.
Some parts require a machine to be in use for several weeks.
We are also capable of carrying out batch machining; indeed, this has been our core business since 1967. For ST DUPONT, we have produced the recesses for the Chinese lacquer on approximately 2 million luxury lighters. We have carried out die-sinking EDM on more than 2 million fibre-optic connectors.
