Commercial Micro Manufacturing - Latest News

ZOLLER Tool Presetter and Measuring Machines Certified with the DEKRA Seal

Tue, 16 Mar 2010 00:00:00 GMT

ZOLLER, based in Ann Arbor, MI, US, a leading manufacturer of tool presetter and measuring machines, tool control and management systems, has always committed itself to offering state-of-the-art technology, highest precision and quality. In addition to a continuous development of its products, ZOLLER has also always focused on documenting this quality. Aside from its certifications according to DIN EN ISO 9001 and DIN EN ISO 14001, the ZOLLER tool presetter and measuring machine product line has now been awarded the DEKRA seal for product safety, providing additional confidence in the company's products.

According to the company, ZOLLER products, now with the DEKRA seal, guarantee the following: usability, longevity, machining and handling check: easy and user-friendly operation of ZOLLER tool presetter and measuring machines and software; technical and electronic documentation of the appearance and workmanship of the presetter and measuring machines as well as a certificate confirming quality: product safety, among other things thanks to the ZOLLER actuator concept for CNC driven axes eliminating the risk of injury; proof of high demand on quality and safety: ergonomic handling, thanks to its design allowing a comfortable working position even during long working processes; product reliability especially in view of growing globalisation and non-transparent competition: maximum quality, longevity and user-friendliness.

DEKRA is an internationally focused expert organisation committed to safety and quality in the everyday relationship between human beings and technology, the environment and mobility. The Stuttgart, Germany, based organisation provides competent and innovative services in the fields of vehicle testing, expert appraisals, industrial services, certification, environmental and building monitoring.

Grinding of Micro Cutting Tools

Fri, 12 Mar 2010 00:00:00 GMT

REQUIREMENTS IN MICRO MILLING AND MICRO DRILLING

There is an undeniable trend in manufacturing towards micro scale. Successful micro machining calls for a different mindset in the procurement and manufacture of suitable cutting tools. Choice of carbide materials and possible coating techniques are important factors, however accuracy and TIR are the two most critical components in grinding micro tools that determine success or failure.

Tool deflection and breakages are much more common in micro machining compared to conventional milling. There are several reasons for this, but chip load is the foremost explanation for such failures. This again highlights the absolute need for accurate tool geometry, the need to be able to precisely measure and the ability to reproduce the geometry consistently.

PRECONDITION OF THE CARBIDE BLANK

The material for micro tools is normally submicron carbide. This material has very fine micro-grain size and uniform carbide particles. Most micro endmills and drills have a common shank of dia. 1/8" or 3 mm. Length ratios vary between endmills and drills. Most miniature endmills have a ratio between cutting length and diameter from 2 and 6 times, while drills go up to 15 times.

Before the cutting geometry can be ground, the cutting part of the blank has to be cylindrically ground. This can be achieved by pinch/peel grinding which is the most accurate method, or by plunge grinding which is more efficient yet less precise.

On endmills, the cutting part of the tool needs to be prepared to a diameter which is slightly over the final cutting size, whereas the cylindrical margin on drills has to be finish ground in this operation. Both require a max. TIR of less than .0001" (1 - 2 microns). Again, this is imperative for endmills also, since any TIR in the pilot will result in unequal deflection during flute and OD grinding ultimately effecting the run-out of the cutting edges.

PREPARATION OF THE DIAMOND WHEEL PACK

For flute grinding of super small endmills, the diamond wheels have to have a substantial edge-retention in order to produce a positive rake on a consistent basis. For example, on a 100 micron endmill (dia. 0.004"), the maximum allowable corner radius of the fluting wheel is less than 10 microns. This kind of sharp corner is hard to maintain on a diamond wheel which typically has a mesh size of 10 microns itself. While preparing the wheel pack for grinding, the operator has to focus the attention on perfect corners and perfect TIR of the wheel. In most cases, this is still a manual skill and it necessitates good dressing and truing equipment. The most accurate way of dressing wheel packs for ultra-small tools is the Rollomatic ProfileSmart which is a 6-axis CNC controlled dressing machine. This machine has the ability to maintain extremely small corners on diamond wheels due to its rigidity and the servo-motor controlled axis movements.

REQUIREMENT FOR GRINDING THE CUTTING GEOMETRY

Run-out on a cutting tool is often attributed to the way the shank is held and supported during grinding. The GrindSmart Nano6 has been designed with a clear vision and offers a new perspective on several fronts. A patented floating workhead with proprietary shank guidance technology allows precise holding and rotating of the shank with zero-tolerance concentricity.

This machine uses both hydrostatic advantages and Swiss micro-precision. Incorporating some of the principles used on other hydrostatic Rollomatic machines, the GrindSmart Nano6 is equipped with 3 hydrostatic axes, providing super accuracy in terms of positioning and achieved surface finish. The hydrostatic oil is constantly being chilled and kept at a highly constant temperature. Therefore the machine has a very high thermal stability which is another basic requirement for grinding super-small tools. The grinding spindle is also temperature controlled and is a direct-drive design that does not need any belt-type transmission therefore eliminating spindle vibrations.

The exterior coolant enclosure is physically disconnected from the machine bed in all dimensions, so peripheral disturbances are not transmitted to the machine bed, resulting in superior cutting edge quality.

The rotary axis that carries the basic workhead is a torque motor which provides an even and smooth revolving movement to achieve a superior finish on ballnose endmills.

POST-GRINDING INSPECTION

A CCD camera is connected to an inspection microscope and the output can be viewed on a computer 21" monitor. Rollomatic uses a system made by Marcel Aubert SA, Switzerland. This system boasts a high-resolution Hitachi camera with a total magnification of 1,800 and an impressive depth of vision. Any dimensional measurements are taken with a VideoCAD software that runs on a PC. A Rollomatic V-block tool holder provides the support and rotational ability to inspect all feature of the cutting tool geometry.

CASE STUDY #1 BALLNOSE ENDMILLS

Client/situation:

This company already made ultra small cutting tools, such as square endmills and drills, but they did not have the ability to produe ballnose endmills. However, the company was one of the few worldwide that could grind endmills smaller than 100 microns (dia. 0.004").

Challenge:

The challenge was to find a machine that can make ballnose endmills in the size range of 100 microns giving a perfect ball contour accuracy and the tool had to be helically fluted including the ballnose.

Actions:

This company purchased a GrindSmart Nano6. In order to grind such a small helically fluted ballnose endmill, this machine has the capability to use a single wheel and grind all features and operations with the various surfaces and corners on just one wheel. This type of grinding is unique, but offers a quicker setup and more stable process due to the fact that there are no resulting errors in using multiple wheels. The process relies on the machine's grinding software VGPro created by Rollomatic which includes this particular capability and a CNC control with 6-axis nano-interpolation.

CASE STUDY #2 REDUCED SETUP TIME

Client/situation:

This company already made miniature endmills including ballnose endmills with existing Rollomatic equipment down to approx. dia. 0.005" ballnose endmills 2-flute.

Challenge:

The setup time was too long resulting in the tendency to make large batches for inventory. This existing method did not offer an effective way to scale down critical dimensions of the process. Main reason was setup time. The steps needed to set up the machine and to arrive at the first good tool add up to a significant length of time. A reasonable response to this was to run large batches and build up inventory. Setup time limited how small the batches could be.

Actions:

This company purchased a GrindSmart Nano6. In order to reduce the setup time, Rollomatic designed this machine with a proprietary shank guidance technology. This eliminates the need to manually calibrate the blank to the center of the workhead, but instead relies on the floating workhead and a complex software program to grind the tools concentric. In addition, the GrindSmart Nano6 is compact, more thermally stable and more precise which all facilitates quicker setup. Concentricity, surface finish and diameter control are key parameters for high performance cutting tools and are very critical if the diameter of the tools is super small, such as under 100 microns (dia. 0.004").

CASTE STUDY #3 VARIABLE HELIX

Client/situation:

This company already made miniature endmills including ballnose endmills with existing Rollomatic equipment down to approx. dia. 0.005" ballnose endmills 2-flute.

Challenge:

The existing equipment did not have the interpolation capability and the accuracy to grind high-performance endmills in the micro range such as variable helix tools. There is a growing evidence that variable helix geometry does not only reduce harmonics during conventional milling, but also in micro machining.

Actions:

This company purchased a GrindSmart Nano6. This machine is fitted with CNC control capabilities and the grinding software tuned and optimized for micro processes. The servo control system of the grinding machine is capable to handle the tight tolerances and the ultra-accurate machining in four dimensions (3 linear plus helical). The GrindSmart Nano6 has nano interpolation that enables simultaneous interpolation of up to 5 axes with the highest possible trajectory and positioning accuracy which is essential for variable helix and unequal index of micro tools. This process relies on the machine's grinding software VGPro created by Rollomatic which includes this particular capability to create and modify geometry with the right accuracy, smoothness and continuity in the nano-size range.

Automated Production in Germany Supported by Tornos

Fri, 05 Mar 2010 00:00:00 GMT

"If you win customers on price, you will also lose them on price," is a statement that Bernhard B�ner, Manager of Manufacturing Equipment and Processes at Prefag Carl Rivoir GmbH strongly believes in. This successful, medium-sized company aims to grow by other virtues such as through innovative ideas, high-precision products and automated manufacturing.

The success story of Prefag, set in idyllic Walzbachtal, Germany, is closely linked with the Swiss lathe manufacturer Tornos. The two companies work in partnership, developing manufacturing strategies to produce absolute quality in largely automated processes.

Prefag was founded in 1954 by Karl Heinz Rivoir, the company now employs over 200 workers and since 2001 has been part of the Magnet-Schultz Group in Memmingen, a prominent manufacturer of electromagnetic actuators for a wide range of industrial applications. Within the network, Prefag has specialised in the manufacture of parts and products in the field of precision and micromechanics. In addition to its expertise in the manufacture of precision turned parts, the company possesses an impressive knowledge of arranging the smallest of components into extremely complex assemblies in the fluid engineering, analogue measurement technology and the automotive and medical engineering sectors. This expertise has noted a new 5,500 m² extension of production space with the pivotal element being the state-of-the-art turning shop with just under 90 lathes, most of them from Tornos.

Besides the conventional materials, the company processes all materials from stainless and acid resistant steels through to exotic alloys. The batch sizes range from one piece to eight million, with tolerances far beyond those that some others might be able to provide. But that is not enough. Prefag does not want to be just a supplier of customer-specific products; its particular strengths lie in system partnership. Together with its customers, Prefag analyses the workpiece and manufacturing process and, where necessary, suggest modifications to the component. At the same time, the Prefag experts will usually already have an eye on the downstream process steps and possible assembly.

There are currently two trends to be seen here. On the one hand, parts are getting ever smaller and the tolerances ever tighter; on the other hand, an increasing number of functions are being integrated into these parts, making them increasingly complex. The manufacture of these parts also places increasingly high demands on the machine tools with milling in all directions, eccentric centre drilling, cross drilling, offset to centre, thread cutting, moulding as well as chasing on the front and back in one set-up. Before buying a new machine, Prefag therefore invests a lot of time and care into choosing the brand. The machines must be fast, precise, productive and, above all, flexible. About fifteen years ago, the responsible people at Prefag were one of the first in Germany to choose the Deco 10 — and they have never regretted this decision to this day.

"The machine simply convinced us of the concept — and even proved itself under tough practical operating conditions, with impressive results. Most machine tool manufacturers get as far as the counter spindle and then think no further", protests B�ner. But money is not only earned at the cutter, but rather in the whole process. "Anyone who simply ejects micro-precision manufactured parts into a crate cannot sit and wonder why his scrap rates might be rising".

Cooperation that benefits both parties
As Tornos and Prefag follow a similar business philosophy, they made a cooperation agreement some time ago. Tornos includes Prefag in the development phase for new machines, where it is able to make use of its years of practical experience. Conversely, Prefag informs Tornos about new demands on precise manufacturing tasks and the two parties then work together to develop solutions. Prefag has no issues with being the pilot user for new Tornos developments and this has applied with the recently introduced Micro 8. This machine has proved to be very temperature stable, which is extremely important for adhering to manufacturing processes with tight tolerances. Therefore, in the new facilities the Micro 8 machines have been acquired and consciously placed in an area in the middle of the hall.

Quality is produced, not measured
A market segment that is currently growing steadily is aeronautics, which of course presents Prefag with new challenges, due to its strict quality guidelines and audits. However, the company mastered these challenges superbly and besides all the usual certificates it also has the approval from the Luftfahrt-Bundesamt (German Federal Aviation Authority).

"Prefag has met its challenges with its state-of-the-art machinery. Anyone who needs to deliver maximum performance to his customers must inevitably make equally high demands of their own machine tool suppliers. In Prefag and Tornos we have two partners who perfectly complement each other and are mutually successful," concluded Mr B�ner.

Measurable Success to be Delivered by Blum at MACH 2010

Fri, 05 Mar 2010 00:00:00 GMT

To facilitate the growing trend in multi-functional Mill/Turn machine tools, Blum NovoTest will be exhibiting its market leading LaserControl NT-H 3D at MACH 2010 on stand 5130. Blum will demonstrate the benefits of the exceptional tool setting system, as well as the exciting range of Z-probes for tool setting and measurement.

Since its UK exhibition debut at MACH 2008; the LaserControl NT-H 3D has proven a resounding success for the German metrology manufacturer. The LaserControl NT-H 3D non-contact tool setting technology provides non-contact measurement of rotating tools as well as the mechanical measurement of non-rotating tools in five approach directions. Blum NovoTest has developed the LaserControl NT-H 3D to cater for the demands of Mill/Turn machine tools. Traditionally turning tools are measured with a mechanical probe and milling tools utilize a laser system, the NT-H 3D eliminates the need for both these types - significantly improving setting times.

The LaserControl NT-H3D can set the radius & tool length for both turning and milling tools and this reduces set-ups and reduces machine downtime. Measuring both sets of tools in one system, the NT-H3D can eliminate the need for two separate systems. Using one complete system, the LaserControl NT-H3D offers exceptional accuracy for all measuring requirements - ideal for machines where space is limited. Competitor products can only offer two separate systems and this reduces accuracy levels and machine accessibility. Alongside the LaserControl NT-H3D will be the Blum range of Z probes that includes the Z-Pico, Z-Nano and the Z-3D. Launched at the end of 2008, the innovative Z-Pico probe is an extremely compact tool length setting and breakage control system for machine tools.

The tiny Z-Pico can carry out machine compensation of the smallest tools in one machine axis. With a total height of only 55mm and a total width of just 28 mm² the Z-Pico is one of the smallest tool setters on the market. The Z-Pico is the ‘little brother' of the well-established Z-Nano tool setter. It is the ideal solution for micromachining applications that often have small machining areas only capable of executing short traverse paths in each axis. It is ideal for monitoring the smallest of tools like gravers, micro drills and small cutters.

The linear working principle of the Z-Pico provides a minimum and torque-free measuring force. This makes the system suitably sensitive to measure the smallest diameters or very long tools. The Z-Pico is able to measure tools down to a diameter of 0.05 mm depending on the geometry and the material of the tool. As with all other Blum probes the trigger signal is not generated via mechanical contact but opto-electronically by shading of a miniature light barrier inside the probe. This guarantees an absolutely wear-free probe with constant reliability under the roughest working conditions.

For slightly larger applications the Z-Nano tool probe allows fast, precise and automatic measurement of tool length and breakage control. Even very long or very small tools up to D=0.1mm can be measured with the highest repeatability (± 0.1 µm) due to the linear actuation of the probe. If the tool touches the probe, a miniature light barrier inside the unit is shaded. This principle is almost free of wear and enables consistently high measuring accuracies over many years. By means of a cable the Z-Nano can directly be connected to the measuring input of the control and needs no additional interface.

Also available in a wireless version, the Z-Nano IR enables machines to be equipped/retrofitted in short time and is also the ideal solution for machines with changeover tables or pallets where no connecting cabling to the measuring system is possible. Several systems can be operated on different pallets in one machine.

Completing the range of Z-probes to be shown at MACH will be the Z-3D probe. Offering tool length and radius measurement whether the tool is standing or rotating, the Z-3D has universal for breakage control, length and radius measurement that is possible from a single cutting edge plus a pre-determined breaking point that protects the probe system from faulty operation. For information and demonstrations of the LaserControl NT-H 3D and the Z-probe range or to enquire how Blum Novotest can resolve all your measurement problems, please visit us on Stand 5130.

Latest Technologies for Micro Molders at MM Live USA

Thu, 04 Mar 2010 00:00:00 GMT

Micro molders who are looking to source the most-cutting edge technologies in their sector, should take time to visit MM Live USA - the micro and precision manufacturing event. Taking place at the Duke Energy Convention Center, Cincinnati, Ohio, from 11th -13th May 2010, MM Live will incorporate many of the leading micro molding suppliers all under one roof.

On the exhibition floor, visitors will find the leading experts in the micro molding field who will be on hand to give advice and demonstrate live their revolutionary techniques. In the machinery field, DESMA TEC will introduce its new micro injection machine called FormicaPlast on booth 1048. The FormicaPlast 2K, a two component micro injection machine, will produce two component parts, made of thermoplastics. Precision machine manufacturer, Sodick Plustech, will show on booth 954 its Micro Molding Series Model: LD20EH2, which will be running a two-cavity thin-wall (0.09mm) application (part weight of 0.0036g).

Other exhibitors with a key focus on micro molding include: SMC Ltd, Accumold, MicroPep, Makuta, TeamVantage, MTD Micro Molding, Micro Engineering Solutions, plus many more. Closely located within the hall will also be Alba Enterprises featuring a Babyplast machine.

Alongside the exhibition are the MM Live Technical Briefing Sessions — a series of free presentations covering all of the key technologies employed in making and verifying precision micro components. Over the course of the three day show, leading experts will take an in-depth look at how micro molding is pushing the technological boundaries.

The Technical Briefings will kick-off on Day 1 with a keynote address from Micro Industry guru, Donna Bibber, who will present a paper entitled ‘Micro Devices Made Possible Using Multiple Material and Micro Manufacturing Technologies' Ms Bibber is President/CEO of Micro Engineering Solutions, a micro design, manufacturing, and assembly and integration company working on critical tolerance-based devices for small to Fortune 50 companies. MES has successfully launched over 1,000 micro projects using various micro manufacturing methods and Donna was recently voted onto the List of 100 Notable People in Medical Devices in 2008.

Following on from this keynote address will be a dedicated Micro Molding session, with papers from Brian Matachun at MTD Micro Molding and Kohei Shinohara, Operations Manager from Sodick Plustech. Brent Hahn from Accumold will also take to the stage with a presentation entitled ‘Prototyping from the Micro Molders Perspective', which will discuss the various methods, challenges and variables for prototyping micro-sized and/or micro-featured plastic parts.

Day three of the Technical Briefing Sessions will have a key focus on Micro Manufacturing in the Medical Industry. The session keynote will be presented by Stu Kaplan, President of Makuta Technics, who will look at ‘The Creation and Production of Micro Molded Microfluidic Components'. Also presenting on the topic of medical molding is the Director of Micro and Miniature Molding at SMC Ltd, Pat Kavanuagh, who will address the ‘Top 10 Tips to Medical Micro Molding'.

As well as micro molding, MM Live USA will provide a global showcase for all aspects of the mass manufacture of small to micro precision parts, whether a company can make them to order or supply the machinery to mill, cut or mold.

MM Live USA is co-located with PDx/amerimold, which incorporates the established MoldMaking Expo and the Time-Compression Expo.

Current exhibitor lists and the full conference program can be found on www.mmliveusa.com, where visitor registration can also be completed.

Nanite Scanning Probe Microscope from Nanosurf Boasts New Methods in Surface Inspection

Thu, 04 Mar 2010 00:00:00 GMT

Nanosurf's Nanite Scanning Probe Microscope (SPM) provides the capability of generating 3D metrology data beyond the resolution of standard optical analysis. With unique ease-of-use features, combined with automation capabilities and efficiency, the Nanite will make nano-surface analysis the industry standard. Multiple, batch-programmable measurements may be performed without SPM knowledge, allowing routine measurements to be delegated to technicians. Standardizing measurements and automatically generating reports will by themselves improve a companies QC, but the added value of high-resolution 3D AFM data over optical analyses will allow users to explore new methods in surface inspection, and will bring customers' QC to a whole new level.

Nanosurf Inc. — Booth 1148

Array of Laser Solutions to be Shown by Oxford Lasers

Wed, 03 Mar 2010 00:00:00 GMT

Oxford Lasers is a specialist in the micromachining industry with expertise in R&D, Application Lab and Laser System integration. Its solutions range from nanosecond, picosecond or femtosecond lasers based on its customer's requirements. The company produces and integrates R&D to commercial micromachining systems, designed for the sole purpose of providing the leading standard of excellence in micromachining. Oxford Lasers will provide a complete micromachining solution to fit any application or simply support job shop needs.

Oxford Lasers — Booth 1047

Range of Best-in-Class Micro Carbide Tooling to be Displayed on PMT Booth

Thu, 04 Mar 2010 00:00:00 GMT

Performance Micro Tool will be showing a range of micro carbide tooling from 5 µm (0.0002") and up. The company will have a variety of tool designs on display, along with application data, videos and photos. With 30 years experience in micro tool manufacturing, Performance Micro Tool will also be available to discuss customers' application needs. Whether standard part or a new design special, PMT will deliver a combination of high quality, exceptional delivery and reasonable price. For more information, visit www.pmtnow.com or call 866-PERFORM.

Performance Micro Tool — Booth 1042

Smallest Parts and Tightest Tolerances With SMC's Micro Molding Capabilities

Thu, 04 Mar 2010 00:00:00 GMT

SMC Ltd. understands that precision matters when it comes to micro molded parts. With part sizes starting at 0.003 cubic inches (0.045 grams) and smaller, it can provide even the smallest parts while still holding tight tolerances. Through its proprietary micro molding process and in-house tooling capabilities, SMC offers complex part geometries with fast lead times and high repeatability. When details are critical, choosing a supplier that understands precision can make the difference. Whether the customer's programe requires a class 7 or 8 clean room, high- or low-volume, SMC's unique manufacturing approach reduces risks for the medical market. The company's efficient material process enables it to deliver yields of 10,000 parts or 10,000 shots per pound minimum, including runner, offering high material yields. Expertise in validation protocols and processes assure conformance to the customer's specific programe requirements, along with experience in a wide variety of materials such as PEEK, Ultem, Bioresorbable and other engineered resins.

SMC Ltd — Booth 942

Precision Injection Molding Machine Offering Outstanding Performance to be Demonstrated by Sodick Plustech

Thu, 04 Mar 2010 00:00:00 GMT

Sodick Plustech will show its Micro Molding Series at MM Live USA. As with other Sodick Plustech precision injection molding machines, the Micro Molding Series employ its patented V-Line Processing System, whereby the melt is first plasticized by a stationary screw (not by a reciprocating screw), and then injected to the tool using a plunger. At the show, Micro Molding Series Model: LD20EH2 is running a two-cavity thin-wall (0.09 mm) application (part weight of 0.0036g). LD20EH2 is 20 ton (US 22 ton) clamping force with 12 mm plunger injection unit, which has a maximum theoretical shot size of 4.5 cc. Sodick Plustech Micro Molding Series offers the linear-motor-actuated hydraulic valve on its machines to achieve outstanding acceleration and deceleration performance, and extremely quick and accurate VP switchover. The linear motor valve uses a very precise linear motor to actuate the spool via a direct coupling and it can accurately produce a measurable response time in as little as 2 msec by oscilloscope analysis, and realize precise and repeatable shot-to-shot motion at speeds down to less than 0.1 mm/sec. Non-toggle clamp actuation, meanwhile, is via direct action with a servo-electric, ballscrew-driven traversing, leading to hydraulic clamp tonnage build to maintain extremely accurate alignment and even distribution of clamping pressure to the tooling.

Sodick Plustech / Plustech Inc. — Booth 954

Trumpf UK to Use MM Live as Springboard to Launch into Micro Manufacturing Industry

Tue, 02 Mar 2010 00:00:00 GMT

The organiser of MM Live 2010, Rapid News Communications, is pleased to announce that Trumpf UK, one of the world's leading companies in manufacturing technology, has signed up to exhibit at the forthcoming show, which takes place at the Ricoh Arena, Coventry, 19th-20th October.

Exhibiting for the first time at MM Live, Trumpf UK will take the opportunity to launch into the micro manufacturing industry its new range of ultra-short pulse lasers. Kevin Roughton, Product Manager of TruMicro Lasers at Trumpf UK commented, "We have chosen the exhibition for the UK launch of our new TruMicro Compact 5000 Series of ultra-short pulse lasers, which are ideally suited for a range of micromachining processes including cutting, structuring, ablation and drilling." The company promises that a visit to its stand could prove extremely worthwhile for anyone involved in the manufacture of small to micro-precision parts.

Duncan Wood, Managing Director of Events at Rapid News, commented, "We are delighted that Trumpf has joined the event as it further confirms the importance of MM Live and the micro manufacturing sector on a national and international level."

The start of 2010 has seen strong exhibition sales from the industry with many companies forecasting a positive outlook and continued growth for micro precision manufacturing in the year ahead. MM Live is delighted to announce that several other companies will be joining Trumpf UK in making their show debut including: Newport Spectra-Physics, Laser Trader, INEX and Applied Laser Engineering.

Other leading manufacturing companies who will be making a return in 2010 include: Rainford Precision Machines, SwissTec AG, Hitachi High Technologies, IBS Precision Engineering, Rondol, Laser Micro Machining, Microfabrica Inc., Optimax, Accumold, Micro Systems Ltd, plus many more.

MM Live is a global showcase for all aspects of the mass manufacture of small to micro precision parts, whether a company can make them to order or supply the machinery to mill, cut or mould. Exhibits cover the full spectrum of micro manufacturing techniques from laser cutting, welding, and micro machining to injection moulding, inspection & measurement, photo etching, handling and assembly.

MM Live 2010 is co-located with TCT Live, the UK's number one product development and manufacturing technology exhibition.

A full exhibitor list can be found at www.mmliveuk.com.

‘Aero Engineering Exhibition & Congress' and ‘The Composites Engineering Show' to be Hosted by Leading Edge Events

Mon, 01 Mar 2010 00:00:00 GMT

B2B Event Organiser ‘Leading Edge Events & Media Ltd' will stage two highly-related events concurrently on 29th-30th September 2010: the ‘Aero Engineering 2010 Exhibition & Congress' — reportedly the UK's only dedicated ‘engineering' event for the UK aerospace community — and ‘The Composites Engineering Show 2010' — a brand new show, servicing the UK's rapidly developing composites design and production engineering community across all applications.

"The response to the co-location in both value chains has been outstanding and we expect a high take up from visitor groups for both shows nationwide," said Event Director Ian Stone, Managing Director of organiser Leading Edge Events & Media.

Aero Engineering 2010 provides a platform tailored to the needs of the UK's aerospace/aviation engineering industries, from specialist aerospace sub-contracting services to advanced machining technology, from test and inspection to modelling and simulation, and much more. "The event fills a vital void in providing a no-nonsense suppliers fair for this demanding, discreet market sector, where buyers and sellers can meet and do business in a focused aero-engineering environment," added Stone.

Building on the success of the inaugural ‘Aero Engineering' (2009) event in Manchester, where some 800+ companies and organisations throughout the UK aerospace engineering supply chain participated, Aero Engineering 2010, in its new ‘central UK' location expects to attract engineering teams from all sides of the UK aerospace industry. A reportedly unique attendance of primes/tier 1 to tiers 2-4 and supporting supply groups, will offer a showcase environment for specialist technologies and service industry supply groups on the show floor.

Importantly, Aero Engineering 2010 will evolve to help visitors quickly identify suppliers, technologies and presentations in their area of interest, using dedicated ‘focus technology trails' that embrace:

Design, modelling, simulation and materials
Machining manufacturing and assembly
Testing and inspection
Avionics/electronics and electrical
Sub-contract/supply chain engineering
Maintenance, repair and overhaul.

Regarding Aero Engineering's parallel Supply Chain Business Briefing, Stone said, "Nowhere else are decision-makers in the UK aerospace engineering supply chain able to hear this level of top tier aerospace programme management presenting opportunities in future aircraft build programmes, collaborative R&D initiatives, export opportunities, industry standards, and more."

Running concurrently on the same show floor, The Composites Engineering Show 2010 reflects the enormous UK-wide demand in composites design and manufacturing, from high volume consumer applications to high performance advanced engineered products. This importance is reflected in the show's support from key stakeholder organisations, including CompositesUK, NetComposites, Knowledge Transfer Network and others

Stone added, "The continuing thirst for information and partnerships for UK companies wishing to work with composites or from those already part of the composites value chain, spurred us to launching the UK's first dedicated showcase for the composites community, mirroring the importance — and growing use — of these advanced materials across all industry sectors, from the obviously synergetic aerospace to motorsport, renewable energy, medical, industrial equipment, automotive and more, and reflecting the Government's recent £22 million endorsement of composites development."

Exhibits and technical presentations at the new Composites Engineering Show will cover all composites types, including fibre reinforced polymers, sandwich and cored structures, fibre metal laminates, metal matrix, ceramic matrix and carbon composites. The event showcases materials manufacturers and suppliers; design, analysis and simulation technologies; processors/processes and production technologies, including machining and tooling; suppliers of composite parts, components and structures; and composites maintenance engineering. The target audience, therefore, is the complete end-to-end design, manufacturing and operational engineering value chain.

Stone concluded, "The combination of multiple advanced engineering groups meeting across the two shows provides infinite opportunities for technology transfer and supply chain networking, and will cement both shows into the UK industry's ‘must attend' calendar."

Visit www.aeroconf.com for details of Aero Engineering 2010 - Exhibition & Congress

Visit www.compositesexhibition.com for details of The Composites Engineering 2010.

Measuring Features on Micro-Machined Components Using Alicona's State-Of-The-Art 3D Optical System

Thu, 25 Feb 2010 00:00:00 GMT

The measurement of micro-machined components has produced significant challenges for measurement and inspection. The nature of the components to be measured have generally steep slopes, complex geometries, multiple forms and varying reflective properties.

Products of this nature at this size can be impossible to measures with tactile systems such as touch probe micro CMMs, stylus type surface finish systems and Interferometers. This is particularly true on items with steep slopes, narrow grooves, with form and small edge radius measurements in the 5-10 µm range.

Alicona has developed the Focus Variation technology, used in its InfiniteFocus system, which allows measurement of these features in an easy-to-use package.

The operating principle of focus variation moves the small depth of focus of an optical system, combined with modulated light, over the object with continuous vertical scanning, producing a topographic 3D data model of the surface. As the distance between the object and objective is varied the variation of sharpness is used for measuring 3D depth information and a dense 3D point cloud is obtained.

This 3D point cloud can be then used to measure features and surface finish and also used for reverse engineering and comparison against CAD data.

Focus Variation will allow the measurement of 'Z' heights from 10 nm up to 22 mm, near vertical walls from 800 with interspacing below 10 µm, radius down to 2 µm with complete surface measurement and characterisation.

The use of this technique enables manufacturers to supply quantitative data to their customers and developers and researchers to confirm that they can achieve design and finishing criteria.