This machine is designed to solve the current problems associated with creating micro- and meso-scale features on miniature components. Lithography-based micro-machining processes are limited to restricted geometry, few materials, slow processes, and expensive equipment. Micro-milling provides a process to make 3-D geometries in a wide variety of materials with a flexible process. The process is suitable for a wide variety of materials including most metals, polymers, and other traditionally machinable materials. It is also more flexible because it is a single-point process with high material removal rates and is driven by mechanical processes rather than chemical reactions.

Many parts created with micro-milling are quite small, however current machine tools that have the accuracies needed for micro-milling are relatively large and expensive.

This machine solves these deficiencies by sizing the machine to match the part sizes it will be making. How It Works This new machine consists of moving stages that are driven by moving-coil actuators and guided by ball-type linear bearings to control the relative position of a cutting tool and the work piece. The machine also utilizes a small ultra-high speed spindle that turns the cutting tool. Both the spindle and work piece are mounted using specialized, highly repeatable couplings to allow for easy interchanging of parts. A constant-force counterbalance mechanism cancels the weight of the vertical stage and work piece. The vertical motor has off-axis movement, which reduces the mass that needs to be offset by the counterbalance mechanism.