Limits of very small manufacturing processes:
Lathe:
Smallest part at a "typical" job shop: min. diameter 1/32" = 800 microns
Smallest hole that can be drilled - 5.9 mils (dia.)
Company Small Parts Inc., Miami Lakes, FL 33014-0650
Repeatable and non-repeatable runout = 2/1e6 of an inch
Milling Machine:
CNC Milling machines: typical accuracy = 2-3 mil = 50-75 microns
source: Accurate Manufacturing Company: 510-653-1414
Smallest drill bit: about 0.0135 mil = 0.34 microns
Smallest end mill: about .4 mm = 400 microns
source: www.Micro100.com
Disco saw:
Width of cut = 64 micron (um)
Max. depth = 640 um
Punching:
Smallest punch diameters = 62.5 mils
Company - Small Parts Inc.
Waterjet Cutting:
Smallest Hole: varies according to material but a
good hole is 1.0mm diameter with
abrasive in solution.
Smallest Kerf: again, varies according to material
but a good line is 0.762mm for a
solution with abrasive and 0.0762mm
without abrasive.
Source: Waterjet Consultants (330)633-7698
Smallest hole and kerf - 10 mils
Source : Composiflex, Inc. PA 16506
Smallest kerf: 0.003"
Smallest hole: 0.003"
Source:Hydrojet Services, Inc., Reading PA
Ultrasonic Milling:
Smallest mill pieces = 40um
Source: Glenmils
Diamond Turning:
Machine accuracy of 1 micron/M. 1/10 wave peak to
valley smoothness.
Source: Oak Ridge Centers for Manufacturing Technology
(800)356-4USA
Figuring of ductile materials on a diamond turning m/c
Source: NASA
Surface finish : 50 angstroms (A)
Figure accuracies : 200 nm
EDM:
Machining accuracy (not quite was was asked for, but pretty close.)
15 microns
Source: Corisma Machine (Taiwan)
Smallest holes - 4 mils
tolerance - +/- 0.2 mils
Source : AMI Machining, Irvine, CA 92614
Smallest hole: 0.0008"/2um
Source: NMT Inc., Nanticoke PA
Laser machining:
Smallest hole and kerf size depends on aspect ratio
desired. For vertical sidewalls and 10:1 aspect ratio,
around 1 micron.
Source: Dr. David Gillegt (800) EXCIMER
Smallest hole and kerf - 10um
Advanced Electronic Packaging Facility,
Cornell University
Smallest hole: 0.0012"/30um -- Source: Industrial Laser Source
Printed Circuit Board:
Min lines/spaces: 2 mil = 100 microns for both lines and spaces
(most boards use 4 mil lines/spaces)
Source: Data Circuits (San Jose)
Smallest trace widths - 4mils
drill hole sizes - 10 mils
Source: Cirexx Corporation
Offset Printing:
2400 dpi = 10 microns
Source: http://www.charrette.com/offset.html
Chemo-mechanical Polishing:
Minimum thickness is 25.4 microns. Maximum
Flatness is 25 RMS.
Source: Aerochem, Inc.
Minimum removable thickness = 0.05 mu
Source: Pall Corporation, New York 11548
Electroplating:
Thickness of deposition: 0.00005 inch
Source: Cal-Aurum Industries,
Huntington Beach, CA
Injection molding:
.001" tolerance for any material = 23 microns
Source: Dawson Tool & Die
Hayward 782-7154
Mechanics Tool & Supply (retailer)
Oakland 568-6060
Ceramic Low Pressure Injection Molding
to 3 mil tolerance
Ceramco
source: http://www.jobshop.com/jobcyclopedia/cyclo/papers/ceramicpartspaper.html
Metal Injection Molding
to 3 mil tolerance
source: http://www.jobshop.com/jobcyclopedia/cyclo/papers/metalinjmold3.html
Kinetics, Inc.
10085 SW Commerce Circle
Wilsonville, OR 97070
503-682-3093
Fax 503-682-1610
Paul A Hauck, Dir. of Sales/Mktg.
Judy Anderson, Cust. Service Rep.
Plastic Injection Molding
to 1 mil tolerance
Hillsman Modular Molding, Inc.
source: http://www.jobshop.com/jobcyclopedia/cyclo/papers/plasticinjmold 3.html
Plastics .0005" -- Schlotter Precision Products, New Hope, PA
Metals .003"/in, 45 RMS roughness -- Talbot Assoc. inc., Springfield NJ
Silk screening:
Electron Beam Writing:
Smallest printable image in resist: ~10nm
Source: Nicholas Rau
2-8897
X-Ray Lithography:
Smallest printable image in resist: ~5nm
Source: Center for Advanced Microstructures
and Devices
(504)925-7070
Chemically Etched Parts
Non/ferrous alloy 0.005-0.0032" thick, tolerances to 10% of
thickness
PMI, Hayward CA
Smallest watch gear:
Smallest screw:
Screw diameter: .0583" to .060"
Source: Harris and Bodini
1122 Harrison St
San Fran, CA 94103
(415)861-8300
fax: (415) 552-0796
COST: $48 for 100 screws
Smallest screw sizes - 62.5 mils
Small Parts Inc.
Smallest DC motor:
6mm diameter
source: http://www.micromo.com
Vigor micromotor
dia - 0.96 inch
Company - Modern Jewellers Supply Inc., Boston, MA
Caliper Resolution
.0005" = 13 microns (Cory Machine Shop)
Best resolution on calipers : 10 microns
Micrometer Resolution
.00005" = 1.3 microns
Source: Cory Machine Shop
mitutoyo digimatic caliper without output. 0-6" with .0005" resolution.
mitutoyo digimatic micrometer w/o output. 0-1" with .00005" resolution.
both can be purchased together from Rutland tool and supply for $227.
16700 E. Gale Ave., City of Industry, CA 91745-0587. Phone#: 800-289-4787.
Fax #: 800-444-4787.
Best resolution with micrometer : 0.01 mm Mititoyo
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This page brought to you courtesy of:
Nick Rau
Ingrid Ma
Patrick Rhiel
Elliot Hui
Behin Behrang
Robert Conant
Ashwin A. Seshia
John Heck