Mass Production

EDM micro-machining
Posalux is a leader in industrialization of micro technologies
for mass production.
Posalux micro-EDM solution for all high-end productive
micro-drilling needs, based on a strong experience
in powertrain automotive applications.
Tapered (conical) hole
200 µm
Step and spray hole
200 µm
Micro Machining
• Hole diameter from 50 µm to 2 mm (0.002 to 0.08 inch)
• Tapered hole with reverse taper up to 150 µm/mm
• Wall thickness / hole diameter ratio up to 12
• All shapes (square, rectangle, ...)
• All conductive material
• Without burr and material deposit, no micro-crack
• Flow stability: +/- 3 %
• Smooth roughness: Ra < 0.2 µm ; Rz < 1 µm
• 6 holes application diameter 150 µm , thickness 0.8 mm:
Erosion time: 25 s / hole
Workpiece cycle time: 192 s / 4 parts floor to floor
µ-EDM
Based on the electro erosion principle, the integrated SARIX µ-EDM
technology allows machining with high quality and efficiency, meeting the
needs of mass production scenarios.
µ-EDM = Micro Electrical Discharge Machining
Electrode guiding system
The integrated advanced electrode guiding system precisely feeds the
smallest electrode available on the market, down to 30 µm.
Electrode guiding system
Specific devices and solutions
• Automatic loading / unloading
• Accurate clamping devices
• Software
• Technology support (µ-EDM parameters)
• User interface options
• Also available with conventional high speed drilling spindIes
4 spindles for an efficient productivity
Quality and expertise
• Flow check system to characterize repeatability and stability
• Optical and fiber non-destructive measurements
to control hole diameter, shape and position
• Scanning Electron Microscope (SEM)
When you buy a Posalux product, you acquire a complete customized
Design of complete production solutions
solution based on our expertise and know-how.
Microfor HP4 EDM / FP1 EDM
Designed for mass production (HP4)
or for flexible small batch production (FP1):
• High productivity
• Process stability
• High positioning accuracy
• Easy machine maintainability
• Multi spindle machine available
Main characteristics:
• Siemens IPC 477D win AC RTX
• Compact water deionization system
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
External Grinding
Posalux is a leader in industrialization of micro technologies
for mass production.
Posalux grinding technology has been developed to provide
industrial solutions for your individual needs.
The Grind Line GX20 is a compact machine designed
for grinding high precision medium and small workpieces.
Technical Data
• Distance between centers approx. 200 mm
•Circularity: < 0.5 µm
• Grindingwheel diameter 400 x 127 mm
•Straightness:< 1 µm
• Grindingwheel width straight head max. 80 mm, •Diameter:
angle head max. 50 mm •Roughness Ra:0.1 µm
• Wheelspeed standard 45 m/s
•Roughness Rz:0.8 µm
• Center height 110 mm •Sphericity: < 3 µm
• Traveldistance X-axis max. 250 mm
•Cylindricity: < 1 µm
±1 µm
• Traveldistance Z-axis max. 400 mm
Basic principle
High precision medium and small workpieces
• Between centers or flying OD grinding
• Straight or anglehead machines (optional manual changeable version)
• Conventional or super abrasive grindingwheel technologies
• Rotary dresser (optional fixed dressing tool)
• Top modern Gap / Crash control device with time signal display
• Process measuring technology
• Matchgrinding with automatic cylindricity correction available
• Special applications on request
Anglehead configuration
Features / applications
Workhead:
• Ultra precise workhead MT5
with interface for quick toolchanging system
• High volume production capable, flexibel, pneumatic actuation with analog sensor control
Tailstock:
• Ultra precise tailstock MT3
including hydraulic pressure circulation lubrication
• Manual or fully automatic precise cylinder correction
Wheelhead:
• High precision spindle with constant peripheral wheel speed
• Manual wheelbalancing integrated within gap control
• Manual or fully automatic wheelguard
and coolant nozzle compensation
Flexible and modular tooling
Dressing systems:
• Ultra precise, rotary dressing system with 4 quadrants control
• Optional static dressing system
Tooling:
• Several high-tech workpiece driving systems available
• Quick change over capability
Dressing process
Quality and expertise
• High-end measurement machine for geometric analysis such as circularity, concentricity, conicity, straightness, ...
• High-end measurement machine for surface and shape analysis such as roughness, ondulation,shape, angle, ...
When you buy a Posalux product, you acquire a complete solution based on
our expertise and know-how.
Geometrical analysis
Grind Line GX20
Designed for mass production:
• Compact machine design for grinding high precision
medium and small workpieces
• Ideal accessibility for set-up
• Ready for handling systems integration
Automation:
• Several standard handling systems available
• Ideal design for cost efficient production grinding
• Fully automatic matchgrinding
• Several additional operations available:
post process gauging, cleaning and deburring
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
High-Tech Micro Drilling and Routing
Posalux is a leader in industrialization of micro technologies for
mass production.
Through constant technological advancements, the Ultraspeed
machine is capable of answering the ever increasing requirements
in the most diverse and advanced application areas.
Machining of INOX and Titanium
Applications
• Machining of non-ferrous metals and materials like:
Aluminium, Brass, polymers
• Machining of ferrous metals like:
Titanium, stainless steel
• Medical industry
Machining of Brass
• Aerospace industry
Machining example
Combi technology - Productivity increase
• High productivity up to 484 holes/min
(e.g. in Brass, diameter 500µm, depth 1200µm)
• Routing and drilling process
• Palletization of template up to 252 plates per loading
or 2 sheets plate 560x350 mm
• Workpiece format Area 710x560 mm
Palletization / loading-unloading
• High speed air bearing spindle up to 200’000 rpm (vibration reduction)
• High speed ball bearing spindle up to 60’000 rpm (high stiffness for routing)
• Cooling process:
by cold air nozzler
or lubrication by microjet (mixture air-oil)
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Tools examples
Machine characteristics
• X, Y and Z axes with linear motor drives
• Tool management system with cassette, Posalux patented tool chain
• Software based on QNX, entirely developed by Posalux
• Spindle speed range from 5 000 up to 200 000 rpm
• Axes acceleration up to 4g
• Controlled depth routing and drilling
• Powerful routing functions
• Automation up to 8 levels for palletization
Quality and expertise
• Optical measurement to control hole diameter and position
• Scanning Electron Microscope (SEM)
• Roughness measurements
When you buy a Posalux product, you acquire a complete customized
solution based on our expertise and know-how.
Drilling positionning
Routing positionning
Mono - Accuracy, productivity and reliability
Designed for flexible and mass production:
• Process stability (running time >20 hours)
• High productivity: up to 484 holes/min
(e.g. in Brass, diameter 500µm, depth 1200µm)
• Drilling accuracy X/Y: ± 4 µm
• Milling accuracy X/Y: ± 6 µm
• Milling accuracy Z: ± 10 µm
• Easy machine maintainability
• High rpm spindles
• Standard or customized clamping systems
• Posalux CNC 3000
Example of palletization
• Linear axis system allowing high dynamic and accurate motions
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
LASER Femto
Posalux is a leader in industrialization of micro technologies
for mass production.
LASER Ultra short pulses FEMTO technology.
Micro Machining
GDI nozzle spray hole (smaller diameter)
• Hole diameter down to 90 μm
machined by FEMTO LASER
• Wall thickness / hole diameter ratio up to 5
• High positioning accuracy
• Excellent flow stability in +/- 1%
• Excellent surface roughness Ra 0.05 μm (like polishing)
• Tapered holes + or - up to 10° full angle
• Flexibility in circular hole shapes machining (ellipses)
• High productivity: less than 2 s / hole
• 6 holes application diameter180 μm, thickness 0.3 mm :
Workpiece cycle time: 14 s ( TWIN configuration )
Hole details - spray hole (smaller diameter)
Advantages of Femto LASER machining
• Heat affected zone avoided due to cold ablation
• No deposits, no recasts
• Machining of a wide range of materials
• Cutting function (ablation) available
• Depending on application: no needs of amount process
LASER source and galvohead specifications
• Femto source down to 230 fs
• Various harmonics available (wave length): nIR, green, UV
• 5 axis galvohead
• Optional: vision system, beam attenuator, shutter, beam analyser
Specific devices and solutions
• Automatic loading / unloading specific solutions
2 localisation systems for hole positioning
• Camera for positioning
LASER head / part load-unload automation
• Focal length measurement
• Dust extraction
• MILLING & FEMTO COMBINED TECHNOLOGIES
Quality and expertise
• Flow check system to characterize repeatability and stability
• Surface roughness measurement
• Optical and fiber non-destructive measurements
to control hole diameter, shape and position
• Scanning Electron Microscope (SEM)
• Study and trials on demand
When you buy a Posalux product, you acquire a complete customized
solution based on our expertise and know-how.
LASER Head and clamping fixture (left)
Vision system, clamping fixture,automation (right)
Microfor HP1 FEMTO LASER
• Mass production one head LASER machine
• Machine class 1 (I), LASER class 4 (IV)
• Siemens 840 D sl 4.5 SP2 HMI operate,
safety integrated CNC
• Linear axis system
allowing high dynamic and accurate motions
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
LASER Micro Jet
Posalux is a leader in industrialization of micro technologies
for mass production.
The water jet guided LASER solution integrated by Posalux.
Micro Machining
500 µm
Diamerter down to 90μm
• Hole diameter down to 90 μm
• Wall thickness / hole diameter ratio up to 3.5
• High positioning accuracy
• Excellent flow stability in +/- 1%
• Excellent surface roughness Ra < 0.5 μm
• Tapered holes + or - up to 6° full angle
• Flexibility in hole shapes machining
• High productivity: less than 3.5 s / hole
100 µm
• 6 holes application diameter150 μm, thickness 0.2 mm :
Workpiece cycle time: 28 s
High quality of roughness and edges
Applications
• Micro-holes machining
• Micro-holes finishing process
• Cutting process
• Non-conventional shapes machining
Part Finishing
Part Cutting
• Automotive industry
LASER beam
• Medical industry
• Watch industry
Lens
Window
Advantages of water jet guided LASER machining
• No continuous focus adjustment needed
Water
20 bar - 500 bar
• LASER beam guided by the water jet
• Heat affected zone avoided due to water cooling effect
• Water jet prevents particles deposition, contamination and burrs formation
• Low running costs
Water
chamber
Total internal
reflection
of LASER beam
Nozzle
Work piece
Work piece
LASER head specifications
• Integrated LASER beam alignment device
• Coupling unit to combine the LASER beam with the water jet
• Vapours fume & dust extraction depending on customer parts and alloys
Specific devices and solutions
• Automatic loading / unloading specific solutions
• No ‘backwall’ issue with dedicated clamping fixture
• Camera for step hole positioning
• High pressure deburring
• Hole shape device “A-AXIS” +/- 3° (+/- 100 μm/mm)
• Washing station
LASER head and coupling unit
Quality and expertise
• Flow check system to characterize repeatability and stability
• Surface roughness measurement
• Optical measurement to control hole diameter, shape and position
• Scanning Electron Microscope (SEM)
• Study and trials on demand
When you buy a Posalux product, you acquire a complete customized
solution based on our expertise and know-how.
Microfor HP1 LASER
• Mass production one head LASER machine
Head with coupling unit (top)
• Machine class 1 (I), LASER class 4 (IV)
Clamping fixture (bottom)
• Available with Nd: YAG or fiber LASER
• Siemens 840 D sl, HMI advanced,
safety integrated CNC
• Linear axis system allowing high
dynamic and accurate motions
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
Milling machining
Posalux mass production solution dedicated to milling process
for material hardness up to 67 HRC / 900 HV
Micro Machining
• 5 axis machine for drilling and milling process
Axis strokes:
Axis X
300 mm
Axis Y
300 mm
Axis Z
70 mm
Axis B0..60°
Axis C0..360°
• Milling Ø 0.1-2 mm (typical for stephole 0.3-0.5 mm)
GDI nozzle step holes machined by Milling
• High positioning accuracy
Accuracy for milling X/Y/Z
+/- 20 µm
Accuracy for drlling X/Y/Z
+/- 10 µm
• High productivity:
Milling time per hole < 0.8 s
Cycle time per workpiece (8 holes) < 13 s
(e.g. for Step holes milling in 1.4112 , 60 HRC, Dia.500µm, Thickness 0.3 mm)
Step hole
Advantages of Milling machining
• Blind hole with flat bottom und controlled radius
• Reduced cycle time compared to other processes
Applications
• Automotive for GDI application
• Automotive for Diesel injection
• Watchmaking industry (brass, stainless steel)
• Medical industry (peek, stainless steel, titanium)
Milling spindle
Milling spindle
• Air bearing spindle
• Rotation up to 60’000 rpm (optional 100’000 rpm)
• Increased tool life (up to 5’000 holes)
• Oil free and grease free operations
• Tool holder HSK E25 balance quality G0.1
Milling spindle
Specific devices and solutions
• Automatic loading/unloading specific solutions
• Tools holder with 12 tools
• Tool break control
• Tool Ø and length control
• Cooling by cold air nozzle
• Optionnal lubrication by microjet (mixture air-oil)
• Deburring station integrated
Integrated tools holder
Quality and expertise
• Surface Texture measurements
• Optical measurement to control hole diameter, shape and position
• Scanning Electron Microscope (SEM)
When you buy a Posalux product, you acquire a complete customized
solution based on our expertise and know-how.
Microfor HP1 Milling
• Siemens 840 D
• Mass production one spindle Milling machine
• Designed for production’s cell integration
• Tools holders specific studies on demand
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
PCB Micro Drilling and Routing
Posalux is a leader in industrialization of micro technologies for
mass production.
Through constant technological advancements, the Ultraspeed
machine is capable of answering the ever increasing requirements
in the most diverse and advanced application areas.
Combi Spindle : Drilling / Routing
Dual or Combi technology - Productivity increase
• High productivity 1 200 holes / min / spindle
(e.g. in FR4, diameter 100µm, depth 300µm)
• Up to 12 spindles per machine
• Two independent X-axes drilling on the same station
• Increased productivity up to100% compared with single mode
• Uses half the floor space of two regular machines
• Doubles the output
• Hole diameter from 75 μm to 6500 μm
• Wall thickness / hole diameter ratio up to 12
Applications
Printed Circuit Board applications
• Printed Circuit Board
• Aerospace industry (Aluminium)
PCB drilling characteristics
Running time about 15 hours / 900 000 holes per panel, Ø 100µm
Printed Circuit Board products:
• Substrates
• Mobile equipment
• Motherboards
• Industrial electronics
• Automotive electronics
Drill bits
Machine characteristics
• X, Y and Z axes with linear motor drives
• Gantry concept - two linear motors driving the Y-axis
• Tool management system with cassette, Posalux patented tool chain
or Asian Tool Change (ATC)
• Software based on QNX, entirely developed by Posalux
• Spindle speed range from 5 000 up to 350 000 rpm
• Axes acceleration up to 4g
• Controlled depth routing and drilling
• Powerful routing functions
• Automation
Printed Circuit Board application
Quality and expertise
• Optical measurement to control hole diameter and position
• Scanning Electron Microscope (SEM)
When you buy a Posalux product, you acquire a complete customized
solution based on our expertise and know-how.
Aerospace aluminium application
Mono and G-line - Accuracy, productivity and reliability
Designed for flexible and mass production:
• Process stability (running time >20 hours)
• High productivity up to 1200 holes/min/spindle/pannel
• High positioning accuracy (99.98% of holes within ±15µm)
• Easy machine maintainability
• Gantry and DUAL technologies available on G-line series
• High rpm spindles up to 350 000 rpm
• Standard or customized clamping systems
• Posalux CNC 3000
• Linear axis system allowing high dynamic and accurate motions
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014
Spark Assisted Chemical Engraving
Posalux is a leader in industrialization of micro technologies
for mass production.
Spark Assisted Chemical Engraving is an innovative solution to
machine glass substrates without material alteration, keeping
transparency properties with high accuracy.
Achievable machining features
Micro Machining
• Hole diameter from 80 µm (0.0032 inch)
• On any glass materials (Borosilicale, Pyrex, ...)
• Glass transparency property not impacted
• Without material deposit and no damages or burrs
• Wall thickness / hole diameter ratio up to 10
Machined micro-hole
• Smooth and clear machined surfaces
Diameter’s tolerance: 5 - 10%
• No clean room facilities needed
Application field
• Electrical circuits: TGV (Through Glass Via)
• Photonics: optical waveguides and interconnects
• Watch industry
• Micro fluidics : grooves, large wall thickness holes
Texturing examples
on micro-hole and micro-channel
• Production of LCD display
• MEMS devices
Chemical engraving
• Material removal thanks to thermo-chemical process
• Physical attack by discharges
• Chemical etching (breaking Si-O-Si bonds by OH radicals)
• High removal rate obtained thanks to micro-force closed-loop regulation
• Process stability by electrolyte circulation and temperature control
Machining specifications
• Drilling speed: 100 µm/s up to 200 µm/s, then 50-60 µm/s
• Groove machining speed: 20-100 µm/s (depth from 100 µm to 1000 µm)
• Tolerances on channel width: 5%
Spark Assisted Chemical Engraving
1 mm
Specific devices and solutions
• Clamping devices
• Specific algorithms to optimize material removal rate
• Technology support (SACE parameters)
• User interface options
Quality and expertise
• Scanning Electron Microscope (SEM)
• Roughness measurements
• Optical measurements to control shape
When you buy a Posalux product, you acquire a complete customized
solution based on our expertise and know-how.
Machining head
Microfor FP1 SACE
• Process stability
• High positioning accuracy
• Easy machine maintainability
Main characteristics:
• Siemens 840D
• Electrolyte quality and temperature control
• Vacuum and filtering systems
• Multi spindle machine available
Posalux SA | 18 F. Oppliger | P.O. Box 6075 | CH-2500 Biel-Bienne 6 | Switzerland
Phone +41 (0)32 344 75 00 | Fax +41 (0)32 344 77 01 | [email protected] | www.posalux.ch | ©2014