Mechanical micro-machining using milling, wire EDM, die-sinking EDM and diamond turning

From among all the different techniques currently applied for micro-manufacturing, this paper focuses on those techniques that can be considered as conventional techniques because of their direct relationship with standard machine tools. The following processes are discussed: ultra-precision milling, thin-wire EDM, die-sinking micro-EDM and diamond turning. Despite the mentioned relationship with conventional machine tools, they all have special characteristics that enhance the capability of the machining principle. The processes are analysed, showing the differences with respect to the corresponding conventional processes and stating their current limitations. A review of the state of the art, applications and potential markets is presented. Finally, the capabilities of these technologies and the other micromanufacturing techniques (lithographic processes) are compared in order to highlight the possible competences and complementariness that they present. (c) 2006 Journal of Mechanical Engineering. All rights reserved.