microcut

Microcut is a term used in manufacturing to describe cutting operations performed at micrometer-scale dimensions to create fine features with high precision. It encompasses a family of micro-machining techniques, such as micro milling, micro turning, laser micro-cutting, micro waterjet cutting, and micro electrical discharge machining (micro-EDM). The goal is to remove small amounts of material with control at the micron level, producing parts for microelectromechanical systems (MEMS), biomedical devices, and other high-precision components.

Techniques and tools: Micro-scale cutting tools—end mills, drills, and inserts with diameters down to tens of micrometers—are used on rigid, accurate machines, often with high-speed spindles and stringent environmental control. Some processes incorporate ultrasonic or vibration-assisted cutting to improve chip formation and reduce wear. Process parameters include small depths of cut, low feed rates, and careful thermal management to minimize distortion.

Materials: A range of materials can be microcut, including metals (aluminum, steel, titanium), polymers, ceramics, and composite materials, though brittle materials pose additional challenges.

Applications and challenges: Common applications are MEMS components, microfluidic channels, precision medical devices, microgears, and electronics housings. Challenges involve tool wear, burr formation, thermal damage, position accuracy, and surface integrity. Metrology is essential, often using optical or electron microscopy and surface profilometry.

History and outlook: Microcut techniques evolved with advances in CNC machining, microfabrication, and precision metrology. Ongoing research focuses on increasing material removal rates, improving tool life, and integrating microcut with additive manufacturing and in-situ sensing.