Future Tooling: Tooling Technology vs. Application Requirement

Lead Division
Metals, Division 7

Other Divisions Participating
Polymer Processing, Division 4
Ceramics, Division 8
IPU (Denmark), Industry

Summary
The accuracy, the geometrical dimensions and the physical characteristics of a final part depends strongly on the shape (quality) of the tool. Especially at microscale level the comparatively small forces, small nominal dimensions and also small tolerances require high-precision tools for the manufacturing of products with high quality. Thus, very precise and accurate manufacturing processes are indispensable for tool-making at microscale and only few manufacturing processes qualify for this task at present. Each manufacturing process is characterised by the process capability and quantitatively expressed by the achieved dimensional accuracy, accuracy of the shape, roughness of the machined surface, defective layer of the machined surface etc.

If all these processes are to be considered for the purpose of microtooling, the capabilities of each individual process should satisfy the requirements of both, tooling and the replication (fabrication) technology. This means that certain accuracy and roughness should be achieved first for the micro tool to work properly and second to satisfy the requirements of the same criterion of the final part to be produced by the tool.

The aim of this cross divisional project is to analyse the current capabilities of the different tool-making processes and to analyse the demands of the replication (fabrication) manufacturing processes. Based on this analysis of current capabilities of tool manufacturing processes vs. product and replication process requirements, the knowledge gap of micro-tool manufacturing will be identified and recommendations for future tool design and manufacturing will be given.

To reach this goal, two working teams will be established: first team (tooling team) analysing the current state-of-the-art in tooling, the second (product team) characterising the requirements of the micro-replication (fabrication) processes. The results of both teams will be reviewed and recommendations for future tool developments techniques (from design to manufacture) will be given to broaden knowledge and improve micro-replication (fabrication) processes.
The tooling teams will consist of specialists of the different tooling processes:

 Micro machining: TEKNIKER, Cardiff
 Etching: Cranfield
 Micro EDM: TEKNIKER, DTU, Cardiff, IPU
 Electroforming: DTU, Cardiff
 Laser machining: Erlangen, Cardiff

The replication team will consist of specialists of the different manufacturing processes:

 Micro forming: Erlangen, Strathclyde, IPU
 Micro injection moulding: TEKNIKER, Cardiff
 Hot Embossing: Cardiff

Status of this Cross-Divisional Project
To be completed March 2008.