Micro‐Milling Opportunities and Challenges
We are all familiar with the phrase “the world is getting smaller.” However, it is not just that the world is getting smaller; practically everything we use is getting smaller.

Computers continue to get smaller, and monitors and TV displays get thinner and thinner. Advances in medical devices enable miniature appliances to be installed inside our bodies; even a tiny camera that can travel through it.

Not only are things getting smaller, they are packed with more components to provide added power and functionality. Mobile phones now function as a computer, video camera and GPS all in one compact unit. Micro‐size components have a wide variety of applications in almost every industry, including aerospace, automotive, electronics, healthcare, information technology, and telecommunication.

All of these product and technology developments are increasing the demand for manufacturing of micro‐scale components and products. These trends present mold makers with new and diverse challenges, ranging from the use of new materials to special mold coatings, milling parts with 0.1mm diameter tools, and achieving sub‐micron‐level accuracy.

At the same time, it is the inherent complexity of micro‐components that brings about new opportunities for mold makers. At a time when production of simple and medium complexity molds is shifting to countries with low labor cost, US and European mold makers can turn to more advanced technologies such as micro‐molds and micro‐milling to maintain their competitive edge.

In this guide, we cover the key machining and software requirements for mold makers that are looking to capitalize on the micro‐milling opportunity.

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