Our capacity to provide high-precision machining services is exemplified in the project highlighted here. This project entailed the creation of mold punch pins for a medical client. The pins were machined from stainless steel to a diameter of 0.500″ and a length of 2.000″. Concentricity and roundness of the pieces met extremely tight tolerances of ±0.000020″ (two hundred-thousandths of an inch). A combination of high-precision rotation and wire electrical discharge machining (EDM) was used to fabricate the parts to meet tolerances that in most cases are considered to be virtually unattainable. This turn (rotation) and burn (EDM) process minimized the amount of pin repositioning required, allowing for maintenance at accuracy throughout the cutting process.
Inspection and quality control of the pieces were accomplished using a Zeiss coordinate-measuring machine, which was able to precisely identify any deviations from the specified part dimensions. Lots were created in quantities varying from 100 to 1000 pieces and were turned around in a period of five weeks after receipt of order. The creation of parts meeting tolerances of this magnitude required a significant amount of engineering involvement in developing and maintaining the process at precise fabrication.
Specifications
Capabilities Applied/Processes
- Primary: Rotational Wire EDM/Turn and Burn
- Secondary: Turning
Equipment Used to Manufacture Part
- EDM Fixtures with Air Bearings – Toolmakers
- Wire EDM
Overall Part Diameter
Overall Part Length
Tightest Tolerances
- Concentricity and roundness within ±0.000020 in. Yes, 20/1 millionth’s of an in.
Material Used
In Process Testing/Inspection Performed
Volume
Delivery/Turnaround Time
Delivery Location
Standards Met
- 2D CAD Drawing
- Customer Specifications
Why Did You Choose This Project to Showcase?
The combination of Wire EDM technology with high precision rotation to attain the tolerances, these tolerances are considered by many to be unattainable! Impossible.
