Microdies

Microdies are precision forming tools designed to produce parts at micro-scale. They are used in stamping, punching, embossing, and molding operations where features range from tens of micrometers to a few millimeters.

Because the scale narrows process windows, microdies require extremely tight tolerances, precise alignment, and smooth surface finishes. Common forms include micro stamping dies (punch and die sets with fine features), micro-embossing dies for metal or plastic, and micro-injection or micro-molding dies used in molded micro-components.

Materials and fabrication: Microdies are usually made from high-hardness tool steels, carbide, or ceramics, and frequently receive wear-resistant coatings such as TiN, TiCN, or DLC. They are manufactured with micro-machining techniques, including precision grinding, micro-milling, and micro-electro-discharge machining (micro-EDM), as well as laser micromachining or electrochemical machining.

Performance considerations include tight tolerances, burr control, fracture resistance of delicate micro-features, and thermal effects from repeated forming. Proper lubrication and debris removal are essential at small scales.

Applications span MEMS packaging, medical devices, microelectronics connectors, and micro-fluidic components, where consistent production of tiny, repeatable features is required.

In research and industry, microdies can also describe miniature dies used in laboratory microfabrication setups, where dedicated tooling supports rapid prototyping and small-batch production.