www.precisionmicro.com
PRECISION MICRO has a strong background in custom designs for defence and aerospace applications. The Company is experienced in the application of Exostar and supplying all aircraft platforms: large civil, business corporate, helicopters, military combat and transport and is ideally placed to meet their rapidly changing requirements in terms of quality, speed, precision and innovation.
The Need for Quality Aerospace and defence engineering has an emphasis on quality that pervades every aspect of its operation. PRECISION MICRO has over 40 years experience in the manufacture of components for safety critical systems. The Company is registered to comply with BS/EN/ISO 9001:2000 and has Civil Aviation Authority (CAA) approval. The Company is proud to have been granted accredited supplier status by major international companies including TRW Aeronautical, Goodrich, BAE Systems, Raytheon, Thales, Westland and Rolls Royce among others.
The Need for Precision Nowhere is the need for precision greater than in aerospace and military applications, industries that set the standards to which others aspire. In many instances this need can only be met by utilising the types and combinations of manufacturing technologies available under one roof from PRECISION MICRO... technologies that guarantee tolerances measured in microns... technologies that are ideal for producing critical components in the majority of compliant aerospace grade materials including high tensile stainless and heat resisting steels, aluminium, aluminium bronze, aluminium lithium, beryllium copper, phosphor bronze, Inconel速, Nimonic速 and Incoloy速 alloys.
aerospace & military
Typical Products
The Need for Innovation The technical expertise of the Company’s engineering support team enables it to undertake specialist development projects for customers, to provide them with cost-effective precision engineering solutions specifically tailored to meet their requirements.
Mechanical Components ● Brazing shims ● Gaskets ● Air intake grilles ● Alternator parts ● Grilles ● Heat insulation shields ● Fuel filters ● Hydraulic shims (flat and formed) ● Precision shims and spacers ● Stencils for glass marking ● Instrument panels ● Dials and pointers ● Fuel Cell components Electronics Components ● Lead frames for component packages ● Lids and stepped lids for sealing ceramic, metal and hybrid packages ● Actuators ● Contacts ● Carriers for multi-chip modules and power components ● Control gear ● Laminations for guidance systems ● Interior lighting components ● RFI Shielding for wiring and electronic components ● Electromagnetic intelligence drive components
e n g i n e e r i n g wi t h i m a g i n a t i o n
Two trends have characterised recent developments in automotive engineering‌ The need for ever-higher levels of precision and tighter tolerances in order to improve operational efficiency and the increasing adoption of electronics and electrics in control engineering. The adoption of fuel cells as a motive force is forecast to eventually revolutionise the automotive industry. PRECISION MICRO has been involved at the embryonic stage of numerous research projects and has already laid down design guidelines for the manufacture of components that boost the power available from fuel cells.
The Need for Precision PRECISION MICRO has a history of precision engineering joint developments carried out with some of the world’s leading tier 1 and tier 2 suppliers to the automotive industry. Competition is also a fertile area for automotive developments and many Formula One teams have come to depend on the precision, attention to detail and speed of service that only PRECISION MICRO provides.
The Need for Innovation Vehicle technology development is under intense pressure from external sources, such as Governments and environmental concerns, as well as market forces. As a result, innovation continues here at a faster pace than in almost any other industry. PRECISION MICRO is at the forefront of vehicle innovation, developing and manufacturing precision components for adaptive cruise control, drive by wire systems, high load vehicle electronics, fuel cells and fuel management and delivery systems.
automotive
Typical Products
The Need for Speed PRECISION MICRO’s choice of manufacturing technologies enables the company to react to customers’ requirements in the shortest possible timescales, supplying prototype mechanical components in hours, yet also able to supply subsequent production quantities at competitive rates.
Mechanical Components Section ● Shims and spacer washers ● High performance gaskets ● Meshes and filters ● Stencils for air bag manufacture ● Airbag components ● Cylinder head gaskets ● Tread plates ● Decorative trim parts ● Injector and fuel management components ● Clutch components Electronics and Electrics Section ● Connectors ● Spring connectors ● High load lead frames ● Lighting frets ● Conductive springs ● Contacts ● Components for engine management systems ● Sensor components R&D Section ● Fuel cell components ● 42V power architecture ● Drive by wire
e n g i n e e r i n g wi t h i m a g i n a t i o n
Over recent years, there has been a fundamental and exciting change in communication technologies, which is having a dramatic effect on the way people live their lives and conduct business. Broadband technologies have demanded innovation in the fixed line sector while wireless communication continues to accelerate. Nowhere is innovation so fast moving as in the Communications industry.
Broadband Innovation Broadband combines the best of conventional electronics, micro electronics and opto electronics technologies in the ‘networked environment for the future’. PRECISION MICRO produces precision components used in the manufacture of fibre optics access, optical transmission, and optical networking equipment as well as components used in the manufacture of opto electronic devices themselves.
Wireless Developments The continued growth of wireless technology is fuelled by innovation... Innovation that in many instances can only be realised by utilising the types and combinations of manufacturing technologies available from PRECISION MICRO. The Company’s precision parts appear in microwave and millimetre wave cellular components and sub systems as well as infrastructure base stations, cellular handsets and electronic defence systems.
The Need for Speed Nowhere is being ‘quick to market’ more of a key competitive driver than in the communications industry. Time saved in the development of a new product equates to months of additional sales time and millions of pounds extra revenue.
communications
Typical Products Component Manufacturing ● Lead frames for component packages with, down-set lands, complete or spot plating ● Lids and stepped lids for sealing ceramic, metal and hybrid packages. ● Carriers for multi-chip modules and power components ● Aerials
PRECISION MICRO utilises a unique combination of manufacturing technologies that can produce prototypes in hours and volume requirements in a cost effective manner to minimise critical paths. Customers are encouraged to involve PRECISION MICRO as early as possible during a project to ensure that mechanical designs are optimised for manufacture in the most cost effective way.
Electronics Assembly ● EMI / RFI shielding enclosures ● EMI / RFI contact strips, fingers, & gaskets ● On board mechanical features, contacts, ground clips, supports, springs, sim holders etc. ● Antennae and micro antennae ● Heat sinks ● Stencils ● Solder performs Base Station Components ● Chassis, and fascia plates R.F.I. Shields ● Centre conductors ● Pole pieces Opto Clectronic Components for ● Receivers ● Transceivers ● Transponder modules ● Amplifiers ● Passives
e n g i n e e r i n g wi t h i m a g i n a t i o n
PRECISION MICRO is ideally placed to meet and in some instances anticipate the rapidly changing requirements of the electronics manufacturing industry, in terms of miniaturisation, speed, flexibility and innovation.
The Need for Precision As the physical scale of electronics components and assemblies reduces so the need for enhanced precision increases, precision which PRECISION MICRO achieves by utilising a unique range of manufacturing technologies in processes that guarantee tolerances measured in microns. With ever higher device pin counts and the trend to ultra fine pitches the need for dimensional accuracy has never been greater. In many instances this need can only be met by utilising the types and combinations of manufacturing technologies available from PRECISION MICRO.
The Need for Speed and Flexibility The short lifespan of today’s electronics products, combined with the ever increasing urgency to get products to market fast, have led to a fundamental change in the technologies needed for prototyping and manufacturing small precision mechanical components. PRECISION MICRO utilises digital and modular tooling that can be produced in hours and is easy to modify; tooling that has a low initial cost, commensurate with the low risk product development strategy sought by many electronics manufacturers.
The Need for Innovation PRECISION MICRO’s choice of manufacturing technologies enables the company to pursue many innovative techniques that ease the manufacture and subsequent use of precision mechanical components in electronics assembly.
electronics
Typical products Component manufacturing: ● Lead frames for component packages to contactless smart cards with post etched rounded leads, down-set lands, complete or spot plating. ● Lids and stepped lids for sealing ceramic, metal and hybrid packages and tubs. ● Carriers for multi-chip modules and power components
Customers are encouraged to involve PRECISION MICRO as early as possible during the design stage of a component. Our process and related design expertise will ensure that any concept or design will be understood and optimised for manufacture in the most cost effective way.
Electronics assembly ● EMI / RFI shielding enclosures ● EMI / RFI contact strips, fingers, &gaskets, ● EMI / RFI shielding universal prototyping kit ● On board mechanical features, contacts, ground clips, supports, springs etc. ● Antennae and micro antennae ● Heat sinks ● Solder masks ● Terminal tags ● Stencils ● Solder performs Box assembly ● Chassis and other mechanical components ● Fascia plates ● Metal dome arrays for tactile membrane switches ● Wiper carrier components
e n g i n e e r i n g wi t h i m a g i n a t i o n
In today’s world, where precision, quality and service are major competitive drivers, there is a growing requirement for close tolerance, metal components. It is these precision parts that hold the key to the smooth and efficient operation of the many finished products. PRECISION MICRO has responded to this challenge by assembling a collection of process technologies that enable the Company to manufacture small 2 & 3 dimensional precision parts in short time frames with little initial investment by the customers; a true low risk option.
The Need for Precision Precision depends on scale and is relative to the manufacturing process employed but the underlying concept pervades every aspect of PRECISION MICRO’s business in its quest to meet or better specified tolerances. The fact that PRECISION MICRO enjoys favoured supplier status with manufacturers of measuring equipment, micro fluidic devices and photonics equipment is testament to the company’s ability to meet these precision requirements.
The Need for Speed and Flexibility The highly competitive nature of many modern markets dictates that new developments should be progressed quickly if they are to succeed. To meet this requirement, PRECISION MICRO utilises manufacturing technologies that depend on digital and modular tooling, enabling prototype parts to be produced in hours and modified in equally short time frames, yet remain commercially viable in volume production.
precision engineering
The need for innovation The Company’s development engineers have a wealth of materials, process and finishing knowledge. Involving them early in the planning stages will ensure that any concept or design will be understood and optimised for manufacture in the most cost effective way.
The need to handle complexity With most manufacturing technologies, complexity is commensurate with cost. Not so with PRECISION MICRO. The Company utilises manufacturing technologies that can produce the most complex of shapes… shapes so intricate that they could not be achieved by conventional machining methods... shapes produced with little or no extra costs to the customer.
Markets Served Typical Products Mechanical Parts ● Fascia plates ● Gaskets ● Clips ● Springs ● Diaphragms ● Mounting plates ● Spacers ● Grilles ● Shims ● Orifice plates ● Print head orifices ● Battery covers ● Clock dials & hands Meshes ● Filters ● Screens ● Sieves ● Explosion panels Optical Components ● Gobos ñ Metal, Glass or Dichroic Optical masks ● Optical encoder discs ● Optical graticules ● Microfluidic and optofluidic devices
e n g i n e e r i n g wi t h i m a g i n a t i o n
Medical PRECISION MICRO supplies thousands of parts used daily by medical professionals. The Company also supplies components to many manufacturers of medical equipment who appreciate the innovative development approach and fast response that PRECISION MICRO provides.
The Need for Precision With the accelerated growth of Minimally Invasive Surgery (MIS) and the micro scale of many implant components, there are ever increasing needs for miniaturisation and precision, demands that in many instances can be met by PRECISION MICRO’s unique range of manufacturing technologies, in processes that guarantee tolerances measured in microns.
The Need for Speed Medical designers are increasingly expected to do far more, in ever-shorter time scales and usually with fewer resources. PRECISION MICRO can supplement these resources with its advanced design capabilities and manufacturing processes that enable prototype quantities of precision parts to be manufactured in hours rather than months. Volume requirements are then manufactured economically; using the same approved manufacturing routes to mitigate risk.
The Need for Quality PRECISION MICRO manufactures to the requirements of all the regulatory standards applicable to the medical industry.Whereas many equipment and instrument components are manufactured in stainless steel, implants may be specified in a range of exotic materials such as tantalum, Nitinol, Elgiloy, tungsten, titanium, cobalt alloy and platinum iridium... materials that are ideal for processing with PRECISION MICRO’s manufacturing technologies.
medical
Typical Products Single Use Devices ● Needles ● Specialist scalpel blades ● Eye surgery blades ● measurement gauges ● Orthopaedic blades ● Blood and fluid filter components Medical designers are encouraged to involve PRECISION MICRO as early as possible during the design stage of a component. Our process and related design expertise will ensure that any concept or design will be understood and optimised for manufacture in the most cost effective way.
Precision Implants ● Stents ● Pacemaker components ● Orthopaedic pins ● Bone reconstruction components Monitoring and Instrumentation ● Medical electronics components ● Lead frames, screening cans, clips, connectors ● Mechanical parts, paddles, chassis parts, shims, fascia plates ● Diagnostic equipment components for blood analysis ● CT scanner parts ● Radio frequency shielding products Surgical Instruments
e n g i n e e r i n g wi t h i m a g i n a t i o n
photo etching
Key Points Micro Precision Minute and highly complex shapes are possible to tolerances of ±0.0125 mm (0.0005").
Photo Etching is an exceptional manufacturing process that produces the most intricate, burr free, stress free, high precision profiles in a wide range of metals, working directly from low cost photo tooling.
Redefining the Possible PRECISION MICRO is a technology leader in photo etching, pushing the boundaries and redefining the possible to provide a true competitive advantage for customers in a wide range of industries. The Company is geared to producing components to the tightest tolerances in the fastest possible time scales and at competitive rates.
Prototypes to High Volume PRECISION MICRO has capacity to meet all volume requirements from a single part to millions of parts and provide a cost effective solution to all customer needs. The Company specialises in combining Photo Etching with other in-house processes to provide unique solutions to customers design requirements.
Low Cost Low risk, low cost set-up with NO expensive hard tooling means low cost set-up with no significant cost penalty for amending and optimising designs. High Speed Samples can be provided quickly while the same technology can produce economical volume quantities; minimising ‘critical development paths’ and reduce ‘time to market’. Material Diversity Virtually all metals can be etched, even those that are hard or brittle. This technique is ideal for machining thin metals and foils. Stress and Burr Free The process does not induce stress or deformation. Components are burr free while temper and magnetic properties remain unchanged. Ease of Use Techniques such as half-etched bend lines facilitate complex hand forming of parts, saving the cost of hard tooling. Integrated marking reduces handling and cost. Finishing and processing combination Combining Photo Etching with other in-house manufacturing processes provides finished components enabling customers to reduce their supplier base. Integrated Quality System (ISO 9001) Assures optimum quality consistency and provides complete material and process traceability.
photo etching Tolerances Material Thickness T ≥ 0.025mm ≥ 0.050mm ≥ 0.100mm ≥ 0.125mm ≥ 0.150mm ≥ 0.200mm ≥ 0.250mm ≥ 0.500mm ≥ 1.000mm
0.001" 0.002" 0.004" 0.005" 0.006" 0.008" 0.010" 0.020" 0.040"
General Tolerances
< 0.050mm < 0.100mm < 0.125mm < 0.150mm < 0.200mm < 0.250mm < 0.500mm < 1.000mm < 2.000mm
0.002" 0.004" 0.005" 0.006" 0.008" 0.010" 0.020" 0.040" 0.080"
Standard 0.025mm 0.001" 0.025mm 0.001" 0.025mm 0.001" 0.025mm 0.001" 0.030mm 0.0012" 0.030mm 0.0012" 12.5% 12.5% 12.5%
Hole size/slot size
Precision 0.0100mm 0.0004" 0.0100mm 0.0004" 0.0125mm 0.0005" 0.0150mm 0.0006" 0.0200mm 0.0008" 0.0200mm 0.0008" 7.5% T 7.5% T 7.5% T
Standard 0.100mm 0.004" 0.100mm 0.004" 125% T 125% T 125% T 125% T 125% T 125% T 125% T
Bar width (mm)
Precision 0.050mm 0.002" 100% T 75% T 75% T 75% T 75% T 75% T 75% T 75% T
Standard Precision 160% T 100% T 150% T 100% T 110% T 75% T 110% T 75% T 110% T 75% T 110% T 75% T 100% T 75% T 100% T 75% T 100% T 75% T
Precision tolerances may be improved with development, and are subject to feature geometry, material type and sheet size.
Product Examples
Design Guidelines Standard material size
typically 300mm wide, by 450mm long 600mm x 1200mm available on request
Centre to centre, or Pitch Tolerance
of the order of +/-0.05% of any given dimension
Profile An etched profile has distinct characteristics, as the metal is chemically dissolved. The edge profile can be controlled and a range of profiles can be achieved. These profiles are very small, but can often be used to provide a product with unique characteristics.
Multi-compartment RFI Shielding A major telecoms manufacturer required several devices to be individually isolated on a pcb. To save valuable space and assembly time, PRECISION MICRO developed a multicompartment screening can in a single piece. Thanks to the half etched fold lines the walls were easily folded into position without the need for hard tooling. The can could be placed automatically and a separate lid allowed for device tuning and potential rework. Metal filter with ultra-fine apertures In response to a customer’s request PRECISION MICRO developed a filter with extremely fine apertures in order to prevent microscopic bodies entering a sensor. The part was re-designed and the Company produced a series of alternatives with various aperture sizes for test and evaluation. Working closely with the customer on the design of the finished product, attachment features where added to the filter to facilitate easier assembly.
3Dpc wire edm electroform laser cutting
Minute Scalpel Blade A medical supplies company required a minute scalpel blade for eye procedures. The selected material could not be machined by conventional means. PRECISION MICRO developed the original design to incorporate an ‘ultra-fine sharp edge’ that could be achieved during the ‘one step’ etching process.
photo etching micro machining precision presswork technical finishing /plating electronics
Precision Micro Limited P.O. Box 162, 30 Curzon Street, Birmingham B4 7XD UK Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • aerospace & military • medical • precision engineering
electroform
Key Points Micro Precision Microscopic sized components and features are manufactured repeatedly to exceptionally tight tolerances (<±0.005mm) with excellent reproducibility.
Electroforming is an ideal fabrication method for products with requirements for very small, very thin, very fine or very precise dimensions and patterns. It is a high precision additive manufacturing process more akin to photographic process than traditional machining.
Expanding the Realms of Possibility Handling design complexity is a further key strength of electroforming. By ‘growing’ components in Nickel (or other metals) on a mandrel, features and tolerances are managed automatically. Minute components and complex features that cannot be achieved by any other manufacturing method can be produced by Electroforming.
Expertise Through Experience For over 40 years PRECISION MICRO has utilised electroforming technology to meet customer requirements for such items as meshes, encoder discs, foils, filters, orifice plates, micro sieves, optical masks, diaphragms, and other fine and intricate components for the broadest range of industries.
Outstanding Definition Components have excellent edge definition and extremely smooth and parallel aperture sidewalls. Selective reduction of material thickness is easily achieved. Stress and Burr Free The process does not induce stress or deformation. Components are naturally flat and burr free. High Speed No hard tooling means no long delivery delays, helping reduce critical paths and ‘time to market’. Production Versatility Unit volumes in tens or millions can be produced economically thanks to large usable surfaces and fully automated electroforming practices. Material thickness can be modified without changing the tooling and designs can be amended and optimised with no significant cost penalty. Integrated Quality System (ISO 9001) Assures optimum quality consistency and provides complete material and process traceability. Finishing and Processing Combination Combining Electroforming with other in-house manufacturing processes and finishing operations provides customers with finished components and enables them to reduce their supplier base and minimise transport costs.
electroform Properties Materials:
Material thickness (t): Part Size: Tolerances: Minimum hole/slot: > 0.05mm thickness Minimum bar-width: Pitch tolerances: Roughness of side walls:
Nickel and alloys with a hardness up to 580 HV, gold, and substantially, any other material that can be plated. Layers can be built up by depositing different materials 0.015 - 0.2mm from parts of a millimetre to 600mm x 600mm general ± 0.010 - 0.015mm, limit ± 0.005mm 0.05mm, 0.3 t 0.015mm + 2t general ± 0.01mm x distance, limit ± 0.005mm x distance Ra < 0.02
Design Considerations An important consideration is the relationship between material thickness and feature size and it is difficult to detail a tolerance level that would suit all circumstances and remain meaningful. As a general rule a tolerance of ± 2 microns is attainable with an economic yield but specific tolerances are determined for specific designs.
Product Examples Microfluidic Device… Medical A prominent manufacturer of medical devices, in conjunction with a leading European Research Institute, developed a blood analyser, which requires the delivery of precise micro amounts of fluid for analysis using
photospectroscopy. This was achieved through the use of high precision microchannels within a vital delivery component to guarantee delivery volume and flow rates. PRECISION MICRO produced the channels by electroforming and achieved exceptionally fine tolerances that allowed precise and effective analysis of the blood sample. Volume requirements could also be met using the same technology that produced initial prototype samples, easing the FDA approval process. Encoder Discs… Control Engineering Encoder disc and linear codestrips perform essential functions in motion control. The greater the degree of control required, the higher the slot count necessary and the greater the precision needed in manufacture. PRECISION MICRO uses both Photo Etching and Electroforming techniques in their manufacture depending on the slot count and tolerances specified. Electroformed discs are highly precise, thinner, lighter (causing less inertia) and more durable than glass or photo etched discs. They are more stable, have excellent concentricity and have slots with smooth, sharp edges that produce a well defined pulse. Optical Alignment Device… Photonics An electronics equipment manufacturer needed a high precision alignment device for machine set-up. The component was designed with high precision micro-aperture light guides that needed a high level of positional accuracy as well as precise diameter and smooth bores. PRECISION MICRO manufactures these to tolerances measured microns using electroforming techniques combined with a high precision, single side, post etching process. By combining manufacturing technologies, PRECISION MICRO is able to optimise production efficiency while maintaining differential feature tolerances and overall positional accuracy.
3Dpc wire edm electroform laser cutting photo etching micro machining precision presswork technical finishing /plating electronics
Precision Micro Limited P.O. Box 162, 30 Curzon Street, Birmingham B4 7XD UK Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • aerospace & military • medical • precision engineering
3Dpc
Key Points Speed Samples for evaluation and testing are available in hours rather than the months taken by conventional production methods. Intermediate production quantities are supplied rapidly to reduce ‘critical path’ times in order to bring projects to market quicker.
3Dpc technology is PRECISION MICRO’s response to customer demands for three dimensional precision components in a rapid timeframe. It is an in-house combination of profiling and high precision forming and is an ideal manufacturing route for a whole variety of small, precision, mechanical parts. Prototypes can be supplied in days while volume quantities can be manufactured to meet the tightest production schedules.
Profiling and Forming Profiles are produced by Photo Etching, Laser Cutting, or Electroforming, each using digital or photo tooling that is fast and economical to produce and simple to modify and optimise. Forming is achieved by using standard, modular, readily available or easily fashioned form tools, reducing the commercial risk while shortening the lead times involved. Finishing options are provided to suit customer needs.
Low Cost The use of low cost tooling throughout the production process reduces ‘entry costs’ for smaller volume projects making them economically feasible. Designs can be amended and optimised with no significant cost penalty. Flexibility 3Dpc technology provides the flexibility to modify and amend designs in hours, prior to full scale manufacture, without the significant and prohibitive cost of modifying bespoke press tooling. Designers can now optimise their designs without encountering huge prohibitive cost penalties and suffering substantial delays. Low Risk The ‘low cost of entry’ associated with 3Dpc technology means less initial investment is required. A product can be proven in the market before expensive press tooling is required, providing a greater degree of comfort for the manufacturer. Volume Roll-out If required, the same optimised digital designs can be used to prepare progressive punch and form tooling so that large volume requirements can be met by the Company’s Presswork facility.
3Dpc Tooling Precision Score Lines Components can be formed without the expense of forming tools. This method is uniquely created when manufacturing the blank. During the process a precision “score” line is laid into the material which is controlled for accuracy, depth and width. This score line is then the basis for the form, ensuring form length and position, enabling the material to be formed in some instances by hand.
RFI Screening cans and lids We have a range of modular tooling to accommodate a wide variety of designs including shape and size to facilitate fast, cost effective delivery of formed parts.
General Tolerances Positional Angular Internal Radii
Up to 25mm 25mm to 100mm 100 mm >
+/- 0.1mm +/- 0.2mm +/- 0.2mm
+/- 1º +/- 2º +/- 3º
0.5 x Material Thickness 0.5 x Material Thickness 0.5 x Material Thickness
As Above
As Above
1.0 x Material Thickness
As Above
As Above
2.0 x Material Thickness
Half Hard Materials As Above
Full Hard Materials As Above
Tighter tolerances available
Soft Material
Product Examples Miniature Brush Contact… Electronics An electronics OEM designed a brush contact that comprises a profiled and formed backing plate with a stamped semi precious metal alloy brush component attached. Using 3Dpc Technology, PRECISION MICRO manufactured prototype parts in days using a combination of photo tooling and standard
3Dpc wire edm electroform
modular hard tooling for forming. Medium volume production requirements were also met using the same process route. The backing plate was manufactured from phosphor bronze and electroless nickel coated after forming. The brush component, formed from Palladium rich alloy, Palinay, was spot welded to the backing plate in a two stage process in order to achieve optimal robust fusion between the two metals. The process was then controlled with an online SPC monitor. PRECISION MICRO’s wide, in-depth process knowledge allowed the customer to rationalise from five process suppliers to a single component source, dramatically improving both quality and reliability of supply. Mechanical Part for Mobile Handset… Communications A major mobile phone manufacturer required a small three dimensional component for prototypes of a new model, with the potential to expand manufacturing volumes if necessary. Despite being minute, the component profile required no less than 5 separate forming processes. This was manufactured in a few days using 3Dpc technology, (less than the time it would have taken to design progressive press tooling) and the parts were also burr free and required no further finishing. Screening Can with ‘Peelable’ Lid… Communications In the development of a new handset, a major mobile phone manufacturer required an RF device to be screened with an ultra low profile screening can. In the event of a malfunction the customer needed to test the device and inspect joints without removing the screening can by conventional de-soldering methods. Ultra low profile and space restrictions prevented the development of screening enclosure with separate lid. Precision Micro Design Engineers produced development volumes of a low profile screening can that incorporated a perforated track around the top that enabled it to be ‘peeled back’ for inspection in the event of a malfunction using 3Dpc technology. When the problems had been identified and addressed the customer reverted to a standard enclosure.
laser cutting photo etching micro machining precision presswork technical finishing /plating electronics
Precision Micro Limited P.O. Box 162, 30 Curzon Street, Birmingham B4 7XD UK Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • aerospace & military • medical • precision engineering
wire edm
Key Points Exotic Materials Wire edm has an exceptional capability to machine exotic materials (Superalloys, Medical grade stainless, Titanium, Hastelloy®, Nimonics, Monels®, Inconels®, Tungsten carbide, Aluminium alloys, Copper, etc.).
Wire edm (electrical discharge machining) is an exceptionally precise, efficient and economical manufacturing route in many applications, allowing customers to design parts for optimum function, without the many restrictions of other metalworking processes.
Versatile Production Wire edm produces exceptionally precise, parallel sidewalls, allowing stacking when machining multiple parts from sheet material. Taper cuts and free curves can be achieved simply.
High Accuracy PRECISION MICRO offers the very latest in computer controlled Wire edm, manufacturing to tolerances of ± 5 microns. The software is common to its milling and turning operations, enabling work pieces to be easily transferred between machines for multi-cavity work and high precision finishing.
High Speed Wire edm reduces or eliminates fixtures and tooling for one of a kind or low run production parts. Finishing is minimised and parts may be used immediately in assembly, minimising the time between design and delivery.
Elimination of Stress and Distortion Because hardened materials can be wire cut, Wire edm eliminates the need for post-machining heat-treating that can cause part distortion. Wire edm is a completely submerged process and imposes very little heat stress on the work piece. Burr-free, Superior Edge Finish Wire edm produced work pieces are accurate and burr-free, with excellent surface finish; ready for immediate use as finished parts. Intricate Contour Capability Highly complex, contoured shapes can be produced, freeing designers to configure their requirements, in a single piece rather than several component parts. Tight Tolerances Because of the absence of machining forces, Wire edm is capable of holding tight tolerances to ± 5 microns. Multiple Components As Wire edm cuts in an exceptionally straight, true and parallel manner, multiple parts can be produced through stacking sheet materials and cutting several components at the same time. Absolute Consistency Because there is no tooling to wear, Wire edm offers superior consistency on every part manufactured.
wire edm Capabilities ● The
widest range of ferrous and non-ferrous materials including hard metals and exotic alloys that are difficult or impossible to machine to such tolerances by other means
●
Material thickness 0.1mm to 225mm
●
Minimum wire cutting diameter 0.1mm
●
Max weight of work piece 350kgs
● Aperture
walls created by Wire edm are parallel, unlike those cut by laser or water jet
● Accuracy ●
+/- 5 microns
Surface finish depends on number of passes and machining speed.
Product Examples Machining of Prototype Parts… Precision Engineering Wire edm, which can accurately machine as programmed, is very effective for directly cutting a small quantity of multiple parts from sheet metal stock. In particular, trial stamping of parts whose final shape is not yet determined becomes unnecessary. Very thin parts which are difficult to blank on a press can be readily obtained in quantities of over 10 to several hundreds when stock sheets stacked together and clamped are machined by Wire edm. Laminations for electric motors are easily produced from silicon steel in this fashion.
Machining of Stamping and Press Tools… Precision Engineering Cutting die, punches, stripper plate, punch plate and other die components can be accurately machined. Since the process of Wire edm readily performs highly accurate machining, It is an established major method of machining press forming dies. The 1-micron per pulse positioning function of Wire edm can easily locate the wire electrode within a 0.005-mm tolerance of the desired position. This feature of Wire edm can very useful for Progressive Tools, which require close pitch tolerance. Fixture for PVD Sputtering… Electronics An electronics device manufacturer required a micro component with a selective controlled coating of ruthenium (a rare member of the platinum group of metals known for its conductivity and hardness properties). The coater required a fixture to hold the components in position and mask the areas not requiring coating Through an in-depth knowledge of the component and its specific geometries, PRECISION MICRO was able to design and manufacture such a fixture to extremely tight tolerances by using high precision Wire edm preceded by initial feature machining on a CNC milling machine. Because both machines utilise the same control software, post alignment is easy and the multi cavity edm machining can be carried out efficiently thanks to an automatic wire threading facility.
3Dpc wire edm electroform laser cutting photo etching micro machining precision presswork technical finishing /plating electronics
Precision Micro Limited P.O. Box 162, 30 Curzon Street, Birmingham B4 7XD UK Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • aerospace & military • medical • precision engineering
technical finishing/ plating
With vast experience in the manufacture of precision metal components, PRECISION MICRO has a wealth of expertise in the selection and monitoring of finishing and technical coatings technologies.
Working Partnerships The Company maintains long standing technical and commercial relationships with some of the worldâ&#x20AC;&#x2122;s leading specialist coating companies and is able to offer the widest range of coatings and finishes to suit customersâ&#x20AC;&#x2122; requirements.
Independent Testing PRECISION MICRO maintains a test laboratory with X-ray fluorescence analysis, hardness testing, coating thickness measurement, solderability testing and micro sectioning etc., to ensure coating quality.
Coatings Development PRECISION MICRO works with suppliers, independent research organisations and universities to develop new coating technologies for the benefit of its customers.
Finishing Solutions Coatings invariably offer a combination of overlapping properties. PRECISION MICRO development engineers are proficient in recommending the right coating to meet individual performance requirements.
Key Points Wear Resistance / Surface Hardness Modifications can be achieved through heat treatment or the deposition of hard coatings such as Nickel or Chromium, nitriding CVD and ruthenium sputtering. Nickel/PTFE provides an inherent degree of lubricity. Corrosion Protection / Solderability From paint and powder coating to nickel and zinc cobalt, the range of available corrosion protective finishes is immense. Tin Lead and Tin coatings preserve solderability and gold and palladium are used similarly for high reliability applications. Surface Appearance (roughness) Grinding, polishing, linnishing, vapour blasting and other post machining operations are available on request. Conductivity / Insulation Electrical and thermal conductivity may be enhanced by the application of a functional coating. Gold may be used for special pcb connector applications whereas passivated Zinc Cobalt is more common for electrical connectors. A variety of laminates and resist coatings also provide dielectric properties. Semiconductor Bonding Gold and silver are used selectively to improve the efficiency of gold wire bonding and are used as a base for die attach on lead frames. Optical / Cosmetic Specific finishes can be requested; matt, bright, semi-bright etc for cosmetic purposes. Underlying surface roughness also has a marked effect on the appearance. Post Manufacturing Assembly A variety of assembly techniques is employed including forming, micro welding, adhesives/bonding etc to meet customer needs.
technical finishing/ plating Product Examples Valve plates & spring plates… Electronics A company that services and refurbishes air and gas compressors needed an economical and responsive source of supply for valve plates and spring plates for reciprocating piston type compressors… a supplier that could handle both manufacture and finishing. The need was for several different designs and sizes, manufactured from stainless and special alloy steels to tight tolerances and heat treated. Flatness and surface finish were paramount but edges had to be uniform and burr free with a slight radius and no sharp corners. PRECISION MICRO was able to meet the requirement and provide supply from a single source. The profiles are laser cut using Capacitive Height Sensing to ensure that the surface finish of the material is not compromised. Heat treatment is carried out in-house and the plates are then vibration deburred (barrelled) to remove sharp corners and any residual oil from the heat treatment process. Because flatness and surface finish are essential to the sealing properties of the plates, each is then double side lapped and inspected prior to shipment, to ensure that the specified tolerances are being met.
Squeegee blade… Electronics Client required a squeegee blade with increased flexibility at the stencil interface which was accomplished by selective thickness reduction during the precision etching process. The blade was specified with a ‘hard coating’ for durability but should also have low surface energy to encourage solder paste ‘roll’ and ease cleaning. PRECISION MICRO recommended a two stage coating process. The initial hard surface was created with a titanium nitride process and the low energy ‘release properties’ by co-depositing nickel with a submicron fluoropolymer. CCD masking plate… Optical / Photonics A major manufacturer of copying machines required a high precision, slot type CCD mask with substantial material thickness reduction around the slot. PRECISION MICRO manufactured the part from 0.127mm beryllium copper and achieved the required burr-free, high edge definition and selective thickness reduction to 25 microns using precision photo etching techniques. A further requirement was that the part should have a durable and even matt black coating to eliminate any possibilities of reflection. PRECISION MICRO developed a proprietary coating process in-house that provided an exceptionally even coverage and proved ideal for the application. High Count Lead Frame for Computer… Electronics A major computer manufacturer asked PRECISION MICRO to design and manufacture a high count lead frame with a leg width at the chip end of less than half of the material thickness (250 µm) to a tolerance of ± 12µm. material requested was Alloy 42, spot silver plated. After extensive trials PRECISION MICRO developed an accurate down-set tooling machine capable of die cutting and applying the Kapton tape accurately along with the necessary plating masks to silver spot plate the central area.
3Dpc wire edm electroform laser cutting photo etching micro machining precision presswork technical finishing /plating electronics
Precision Micro Limited P.O. Box 162, 30 Curzon Street, Birmingham B4 7XD UK Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • aerospace & military • medical • precision engineering
RF/microwave components Engineers are increasingly utilising higher radio frequencies to meet the ever-increasing performance demands of communications applications, from broadcast communication and data communications networks to cellular phones and even deep space communication. The stronger electromagnetic field effects caused by these frequencies of 1GHz and beyond, increases the ‘interference’ problem and can induce ‘cross talk’, even between remote circuits; problems that must be addressed by design and effective shielding at both board and enclosure level. PRECISION MICRO has a wealth of experience in the design and manufacture of bespoke shielding components to help overcome such problems. The Company also has experience in the manufacture of many other precision microwave components including pole pieces, centre conductors and a wide range of precision microwave antennas.
Microwave antennas Microstrip antennas, RF microwave antenna arrays, patch antennas, radiating plates and antenna shields used for a wide variety of microwave applications in both military and commercial markets including communications, telemetry and tracking. Microwave pole pieces and centre conductors Bespoke precision metallic components used to help complete the magnetic circuit, maximising the field in the ferrite material and reducing the stray field outside the device. One-piece screening cans Bespoke one-piece cans with half etched fold lines and ‘Quiet’ construction features for outstanding attenuation and excellent coplanarity. Available fully formed or flat-pack. Two-piece screening cans Custom cans with removable lids, designed to protect sensitive components from noise while giving access for rework and adjustments. Removable, spring finger lids provide easy access to the enclosure contents and maintain high attenuation in service. Labyrinth (Multi-compartment) screening cans An effective alternative to multiple cans, cost effective to produce and economical in terms of assembly time and real estate management. Separate lid, provides enhanced accessibility for rework or the tuning of devices.
Single-piece drawn screening cans Manufactured from a single piece for complete integrity and optimum attenuation in high frequency applications. Connector shields Connector shields isolate signals from the effects of electromagnetic interference, where two or more conductors are joined. Enclosure shields For use in non-conductive enclosures, these fabricated shields provide a level of EMI/RFI screening for electronics equipment and apparatus, even isolating multiple board configurations. They can also direct and contain potentially harmful emissions. Connector, socket and enclosure insert shields Design specific shields for connectors, sockets and other enclosure inserts. May incorporate mechanical spring contacts and spring finger attachment features. Conductive gaskets Bespoke gaskets with integrated springs ensure optimal electrical contact between enclosure and lid or door. Usually manufactured from nickel silver or beryllium copper, they provide superior mechanical performance and grounding continuity. Vents, grilles, meshes and windows Designed for consistent shielding while allowing cooling air to circulate through equipment cabinets and enclosures, some mesh designs also permit optical viewing.
RF/microwave components Materials & Coatings
Packaging & Presentation
• A wide range of materials is available from stock, including brass, nickel
• Flat-pack, with half etched form lines • Fully formed with half etch form lines • Formed and tray packed with orientation • Tape and reel for small items
silver and mild steel. Tin-plated steel and other high permeability materials for shielding low frequency applications (transformers, coils etc) Non-ferrous materials (tin plated copper, phosphor bronze and beryllium copper) are preferred above 200MHz for microprocessors, fast switching devices, power supplies etc.
• Plating may be specified to improve the attenuation performance • Tin and solder plating enhance solderability. • Dielectric coatings area available for internal insulation
Design Features ‘Quiet’ finger-joint corners
Pick and place lands for
for improved attenuation.
automatic placement.
Location pins/locks for securing
SMT feet provide a greater
screen during SMT and manual soldering.
solderable area for attachment.
Integral marking✌ part numbers and customer logos can be included at no extra cost.
‘Quiet venting’ provides maximum airflow for power devices, with good attenuation.
Serrated base edge for solder
‘Quiet’ finger clip lids for easy
Flat pack for economical storage.
flow equalisation.
fitting, optimum contact and good anti-rattle performance.
SAM, Solder Anti-Migration feature.
3D pc wire edm electroform laser cutting photo etching precision presswork technical finishing/plating
electronics
Precision Micro Limited Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • areospace & military • medical • precision engineering
RF Screening System
Patent Pending
Precision Micro RF SCREENING SYSTEM This is a system produced to enable developers and small scale electronic producers to create on board screening for devices in a simple , quick and efficient manner. The product consists of various width metal strips which incorporate etched bendlines to enable the strip to be readily formed to any profile thus accommodating on board components whilst at the same time keeping the detachable fixing pins aligned to a standard 0.1-inch matrix. The 0.1-inch spacing of the fixing pins enables the screening system to be readily fixed to standard matrix board for simple prototyping etc. The pins also incorporate a slight stand-off so that when the unwanted fixing pins are snapped off there is sufficient clearance to avoid shorting tracks on the upper surface of the board. As well as the strips to form the profile of the screening can there is also a lid section, which has bend lines produced at right angles to each other on either side to enable the lid to be trimmed to size with out the need for tools. The design of the bend lines is such as to produce a matrix of holes on a 0.1inch pitch to correspond with the pins on the side strips. This enables either temporary attachment of the lid by simply bending pins over or a more permanent fixing by soldering.
Precision Micro RF ABTASTSYSTEM Dieses System wurde produziert, um Entwicklern und kleinen Elektronikproduzenten zu ermöglichen, bordinternes Abtasten von Geräten auf einfache, schnelle und effiziente Weise zu schaffen.
SYSTEME DE BLINDAGE HF de Precision Micro Ce système est prévu pour permettre aux développeurs et aux petits constructeurs électroniques de créer un blindage intégré des dispositfs, à la fois simple, rapide et efficace. Ce produit est composé de lames métalliques de diverses largeurs comprenant des lignes de pliage gravées afin que la lame puisse être mise à la forme facilement et puisse ainsi contenir les composants de la carte tout en maintenant les chevilles de fixation amovibles alignées dans une matrice standard de 0,1 pouce. L’espacement de 0,1 pouce des chevilles de fixation permet de fixer facilement le système de blindage à la carte matrice pour un simple prototypage etc. Les chevilles comprennent également un léger retrait de sorte que quand les chevilles inutiles sont cassées, il y a suffisamment d’espace afin d’éviter de court-circuiter les pistes sur la surface de la carte. En plus des lames qui forment le profil de la boîte de blindage, il y a aussi un couvercle qui a d’un côté des lignes de pliage perpendiculaires les unes aux autres pour que le couvercle puisse être coupé à la dimension voulue sans outil. Les lignes de pliage sont conçues pour produire une matrice de trous à entraxe de 0,1 pouce afin de correspondre aux chevilles des lames latérales. Ceci permet de fixer le couvercle provisoirement en repliant simplement les chevilles ou de façon plus permanente par brasage.
Precision Micro RF SISTEMA DI SCREENING Si tratta di un sistema prodotto per consentire agli sviluppatori e ai produttori elettronici su piccola scala di creare schermi on-board per dispositivi in modo semplice, rapido ed efficiente.
Das Produkt besteht aus Metallstreifen von unterschiedlicher Breite mit geätzten Kurvenlinien, um das Formen des Bandes in jedes beliebige Profil zu ermöglichen und damit bordinterne Komponenten aufzunehmen und gleichzeitig die abnehmbaren Fixierstifte mit einer standardmäßigen 0,1 Zoll Matrix ausgerichtet zu halten.
Il prodotto è composto da strisce di metallo di diverse larghezze che incorporano linee di piegatura incise per consentire la facile formazione della striscia secondo qualsiasi profilo, per contenere i componenti on board tenendo allo stesso tempo i pin di fissaggio rimovibili allineati ad una matrice standard di 0,254 cm.
Der 0,1 Zoll Abstand der Fixierstifte ermöglicht die einfache Montage des Abtastsystems auf einer standardmäßigen Matrixkarte für einfache Protoypenkonstruktion usw. Die Stifte sind außerdem mit einem geringen Abstand versehen, damit beim Abbrechen der nicht erforderlichen Fixierstifte genügend Abstand vorhanden ist, um Kurzschluß der Spuren auf der oberen Fläche der Karte zu vermeiden.
La distanza di 0,254 cm dei pin di fissaggio consente il facile montaggio del sistema di screening alla scheda matrice standard per la semplice prototipizzazione, ecc. I pin incorporano anche un leggero distanziamento così che quando i pin di fissaggio non richiesti sono rimossi è presente uno spazio libero sufficiente per evitare il cortocircuito delle piste sulla superficie superiore del circuito.
Neben den Bändern zum Formen des Abtastprofils kann auch ein Deckelsektor vorgesehen werden, der mit Kurvenlinien im rechten Winkel zueinander auf beiden Seiten versehen ist, um den Deckel ohne Werkzeug auf Maß zurichten zu können.
Oltre alle strisce per formare il profilo del contenitore di screening c’è anche una sezione del coperchio, che presenta linee di piega prodotte ad angoli retti l’una all’altra su entrambi i lati per consentire la rifinitura del coperchio delle dimensioni richieste senza il bisogno di utensili.
Die Kurvenlinien sind ausgeführt, eine Matrix von Löchern in 0,1 Zoll Teilung zu produzieren, um mit den Stiften am Seitenband übereinzustimmen. Dies ermöglicht provisorische Befestigung des Deckels durch einfaches Umbiegen der Stifte oder eine mehr permanente Befestigung durch Löten.
Il design delle linee di piegatura è tale da produrre una matrice di fori su un passo di 0,254 cm per corrispondere con i pin sulle strisce laterali. Questo consente o l’attacco temporaneo del coperchio semplicemente piegando i pin o un fissaggio più permanente con la saldatura.
EMI/RFI shielding •
• • • •
A wide range of materials is available from stock, including brass, nickel silver and mild steel. Tin-plated steel and other high permeability materials for shielding low frequency applications (transformers, coils etc) Non-ferrous materials (tin plated copper, phosphor bronze an beryllium copper) are preferred above 200MHz for microprocessors, fast switching devices, power supplies etc. Plating may be specified to improve the attenuation performance. Tin and solder plating enhance solderability. Dielectric coatings area available for internal insulation.
PRECISION MICRO has a wealth of experience in the design and manufacture of screening cans and other shielding components and has pioneered technologies that have expanded both the scope and efficiency of on-board EMI/RFI protection. PRECISION MICRO believes that EMI/RFI screening should be designed to suit the application and not vice versa. Because bespoke solutions can be produced in a matter of hours, there is little justification for maintaining stocks of standard components with ‘compromised design’. In many instances made-to-measure cans are more economical than standard types.
•
One-piece screening cans Bespoke one-piece cans with half etched fold lines and ‘Quiet’ construction features for outstanding attenuation and excellent co-planarity. Available fully formed or flat-pack.
Connector shields Connector shields isolate signals from the effects of electromagnetic interference, where two or more conductors are joined.
•
Enclosure shields For use in non-conductive enclosures, these fabricated shields provide a level of EMI/RFI screening for electronics equipment and apparatus, even isolating multiple board configurations. They can also direct and contain potentially harmful emissions.
One-piece screening cans with peelable tops Tops can be removed easily to allow inspection without subjecting the board to a further thermal excursion. Peeling off the lid is achieved using a simple hook tool or tweezers. Can be resealed with a lid if required.
•
Two-piece screening cans Custom cans with removable lids, designed to protect sensitive components from noise while giving access for rework and adjustments. Removable, spring finger lids provide easy access to the enclosure contents and maintain high attenuation in service.
•
•
Socket and enclosure insert shields Design specific shields for sockets and other enclosure inserts. May incorporate mechanical spring contacts and spring finger attachment.
•
•
Labyrinth (Multi-compartment) screening cans An effective alternative to multiple cans, cost effective to produce and economical in terms of assembly time and real estate management. Separate lid, provides enhanced accessibility for rework or the tuning of devices.
•
Single-piece drawn screening cans Manufactured from a single piece for complete integrity and optimum attenuation in high frequency applications.
Conductive gaskets Bespoke gaskets with integrated springs ensure optimal electrical contact between enclosure and lid or door. Usually manufactured from nickel silver or beryllium copper, they provide superior mechanical performance and grounding continuity.
•
Vents, grilles, meshes and windows Designed for consistent shielding while allowing cooling air to circulate through equipment cabinets and enclosures, some mesh designs also permit optical viewing.
e n g i n e e r i n g wi t h i m a g i n a t i o n electronics • communications • automotive • areospace & military • medical • precision engineering
Precision Micro Limited Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
w w w. p re c i s i o n m i c ro. c o m
www.precisionmicro.com
3Dpc wire edm electroform laser cutting photo etching Precision Micro Limited micro machining
Tel : +44 (0)121 380 0100 Fax : +44 (0)121 359 3313 e-mail : info@precisionmicro.com
precision presswork technical finishing /plating electronics
e n g i n e e r i n g wi t h i m a g i n a t i o n
• communications • automotive • aerospace & military • medical • precision engineering