Fabrication of mass micro-holes using the hybrid precision extruded-wax electroforming and micro-EDM processes

Shun Tong Chen, Albert Wen Jeng Hsue, Tsu Sheng Luo

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 μm in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70°C of water to reveal the final product-a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery without taper and burrs. It is expected the proposed approach contributes significantly to the mass production processes of micro precision holes with a cost effective way.

Original languageEnglish
Pages (from-to)349-356
Number of pages8
JournalJournal of the Chinese Society of Mechanical Engineers, Transactions of the Chinese Institute of Engineers, Series C/Chung-Kuo Chi Hsueh Kung Ch'eng Hsuebo Pao
Volume33
Issue number4
Publication statusPublished - 2012 Aug 1

Fingerprint

Electroforming
Waxes
Fabrication
Nickel
Extrusion dies
Substrates
Costs
Drilling
Metals
Water
Temperature

Keywords

  • Electroforming
  • Extruded-wax
  • Micro-EDM
  • Micro-holes
  • Peck-drilling

ASJC Scopus subject areas

  • Mechanical Engineering

Cite this

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abstract = "A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 μm in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70°C of water to reveal the final product-a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery without taper and burrs. It is expected the proposed approach contributes significantly to the mass production processes of micro precision holes with a cost effective way.",
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N2 - A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 μm in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70°C of water to reveal the final product-a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery without taper and burrs. It is expected the proposed approach contributes significantly to the mass production processes of micro precision holes with a cost effective way.

AB - A hybrid process combined precision extruded-wax electroforming with micro-EDM for 100 micro-holes mass production is implemented in this study. It can produce mass micro-holes of 126 μm in average diameter in a cost-effective batch way. First, EDM peck-drilling is adopted to perforate a substrate of SUS304 plate with micro through-holes. Two miniature devices including an extrusion die and a deposition mould for electroforming are then designed and implemented. The temperature of the oily wax, serving as an excellent sacrificial material, is carefully controlled to obtain an array of precise micro pillars. Then, a precision electroforming of thick nickel metal-layer onto the substrate is involved. The wax mould is then completely removed by heated 70°C of water to reveal the final product-a perforated mass micro-holes array of nickel with 150mm thick. Experimental results show that the finished mass micro-holes have uniform diameters and precise cylindrical periphery without taper and burrs. It is expected the proposed approach contributes significantly to the mass production processes of micro precision holes with a cost effective way.

KW - Electroforming

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KW - Peck-drilling

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