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Micro Machining

Micro machining is a type of manufacturing technique used to produce small and precise parts, components, and structures. This manufacturing process involves using advanced technology to cut and shape materials at a microscopic level. Micro machining typically uses sophisticated CNC (Computer Numerical Control) machines and specialized cutting tools to create intricate and complex features. The process is commonly used in applications such as the CNC machining medical, aerospace, and electronics industries, where precision is paramount. The process demands a high level of technical expertise and equipment and can be used on a variety of materials including metallic alloys, ceramics, and plastics.

Different Micro Machining Services

Micro Precision Machining

Micro precision machining is a specialized process that is used to manufacture small and intricate parts with high levels of precision. This manufacturing process involves cutting, shaping, and drilling materials at a microscopic level, using advanced CNC (Computer Numerical Control) machines and specialized cutting tools. The process is commonly used in industries that require precision, such as aerospace, medical, and electronics.

Small Part Machining

Small part machining is a type of manufacturing process that involves creating intricate and detailed parts, typically with dimensions of a few millimeters. This process uses advanced CNC (Computer Numerical Control) machines and specialized cutting tools to create small, precise shapes and features. Small part machining is commonly used in industries that require precision components, such as medical devices and electronics. The process demands a high level of technical expertise and equipment, and can be used on a variety of materials, including metals and plastics.

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Medical Precision Machining

Medical manufacturing refers to the production and distribution of medical devices, equipment, and supplies used in the healthcare industry. It involves a complex process that includes the design, development, testing, and production of medical products. This includes a wide range of products such as surgical instruments, prosthetics, diagnostic equipment, imaging systems, and drug delivery systems.

At Falcon Swiss Machine Shop, One of the key advantages of Swiss machining is its ability to produce parts with high accuracy and consistency. This is especially important in medical manufacturing, where precision is critical to ensure the safety and efficacy of medical devices.

4 Main Ways of Medical Device Machining at Falcon

1. 5 axis machining

Falcon 5-axis machining process is particularly suited for the machining of high-accuracy, intricate geometries and can significantly improve processing efficiency and reduce processing time. Five-axis machining has wide applications in industries such as aerospace, automotive, medical, and defense.

2. Swiss machining

Swiss machining technique is particularly suited for long and slender parts for medical devices. Our CNC Swiss machining service can maintain exceptional precision and repeatability, making it ideal for high-volume production runs that require consistent quality and accuracy for the medical industry.

3. Micro machining

Micro machining is a critical process in the production of miniature components used in medical applications. It involves the use of precision tools and machines to create small parts with intricate geometries and tight tolerances.

4. Sinker EDM and WEDM

Sinker electrical discharge machining (EDM) and wire EDM (WEDM) are advanced machining processes that utilize electrical discharges to remove material from workpieces. Sinker EDM is ideal for producing complex shapes with sharp internal angles and deep ribs, making it well-suited for the fabrication of high-precision medical components.

Falcon Capacities of Medical Parts Machining & Manufacturing

(1) 300+ Equipment: Falcon has 300 + production and testing equipment: mainly CNC lathes, machining centers (including not limited to Japan TSUGAMI, Taiwan King, etc.), traditional turning and milling, welding, internal and external grinding, surface grinder and EDM (mid-running and slow-running wire); Testing equipment includes spectrograph (ROHS), OES, CMM, projector, altimeter, height gause, etc.

(2) Accuracy: The general accuracy our machine can control is ±0.01mm, and the limit accuracy is ±0.001mm. Precision gear machining module in the range of 0.3-15, size 0-1000mm, DIN 5-9 accuracy.

(3) Processing Capacity: Falcon has accumulated a lot of project experience in mass processing. We can produce at least 1,000,000 pieces in one month, providing one-stop service from one-off prototypes to millions of units for customers in all industries.

(4) Surface treatment: Falcon has at least 30 types of surface treatments. We can meet the specific types of surface treatment requirements of medical customers, such as corrosion protection, rust prevention, etc. Commonly processed surface treatments include anodization, plating, polishing, etc.

4 Keys about Falcon of Medical Manufacturing Quality and Assurance

1. We maintain international certifications such as ISO 9001:2015 and ISO 16949 to save new customers of our high-volume medical parts from the third-party audit costs that come with choosing a more powerful supplier like Falcon.

2. PPAP Compliance: PPAP is used for quality control in the production process of medical devices or components. Falcon provides PPAP to medical industry customers to verify that our engineers have correctly understood all requirements of the customer's engineering design records and specifications. This also proves Falcon's strong supply capacity to continuously meet these requirements during actual production.

3. Process FMEA: Falcon's engineering team carefully analyzes the potential failures and consequences of parts and production processes according to the FMEA process after receiving customer drawings. Necessary measures are taken in advance to help medical industry customers avoid all risks before formal production, improving product quality and reliability.

4. AQL Inspection Standard: AQL stands for ACCEPTANCE QUALITY LIMIT. The choice of quality level is a focus of attention for both suppliers and customers. As a compliant supplier, Falcon is proficient in strictly sampling and inspecting batch products' quality according to the quantity of medical parts batches and the customer's inspection level requirements. So far, our produced medical parts have a high probability of passing the AQL standard, up to 99.99%. AQL has different sampling quantities for different requirements, and our medical customers usually use general level II standards for appearance inspection and special inspection S4 standards for size sampling. Refer to the AQL page for detailed standards and inspection quantities.

5 Typical Medical Device CNC Machining Parts That We Make

Our CNC technologies such as Swiss machining is a versatile and reliable process that can produce a wide range of medical parts with high precision and accuracy, making it an important tool for medical device manufacturers.

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Precision Titanium Machining

Why is Titanium So Hard to Machine?

Titanium, as a challenging material, has a unique combination of properties in terms of high strength, high temperature, chemical reactivity, and elasticity. Due to its strength and tendency to harden during processing, it is difficult to cut using traditional machining techniques. Therefore, Swiss machining is the best choice in general.

Falcon Swiss machine shop is an expert in titanium machining and can ensure successful and efficient processing of titanium materials. We have a deep understanding of the unique properties and challenges of titanium and have developed specialized techniques and tools to overcome these challenges. Contact us now for your titanium manufacturing needs!

Advantages of Titanium Materials in Swiss Machining

Titanium is a widely used material in Swiss machining due to its unique properties and numerous advantages. Here are some of the advantages of using titanium materials in Swiss machining:

High Strength-to-Weight Ratio: Titanium has an excellent strength-to-weight ratio, making it a popular choice for parts where weight reduction is critical. It is approximately 40% lighter than steel but has similar or greater strength.

Corrosion Resistance: Titanium has excellent corrosion resistance, particularly in harsh environments such as seawater or acidic environments. This property makes it a popular choice in the aerospace and marine industry. Using titanium materials in Swiss machining ensures long-lasting, corrosion-resistant parts.

Biocompatibility: Titanium is biocompatible, meaning it does not react with biological tissues or fluids. This property makes it an ideal choice for medical implants and devices. Swiss machining allows for the precise fabrication of complex medical components using titanium, ensuring a high degree of accuracy and compatibility with the human body.

High-Temperature Resistance: Titanium has a high melting point and can withstand high temperatures without deforming or losing strength. This property makes it suitable for use in high-temperature applications such as jet engines and gas turbines.

Low Thermal Expansion: Titanium has a low coefficient of thermal expansion, which means it expands and contracts minimally with temperature changes. This property is advantageous in applications where dimensional stability is critical, such as precision instruments or optical devices.

What is the Best Titanium for Machining?

In Swiss machining, different grades of titanium can be used based on the specific requirements of the application. The selection of titanium grade depends on specific application requirements, such as strength, corrosion resistance, and biocompatibility. Here are some Falcon commonly used titanium grades in Swiss machining include:

Grade 2: Commercially pure titanium with excellent corrosion resistance and high strength.

Grade 5 (Ti-6Al-4V): Titanium alloy with a balance of strength, corrosion resistance, and formability.

Grade 9 (Ti-3Al-2.5V): Titanium alloy with good weldability, high strength, and corrosion resistance.

Grade 23 (Ti-6Al-4V ELI): Variant of Grade 5 with extra-low interstitials, commonly used in medical applications.

The best grade of titanium for machining depends on the specific requirements of the application and the machining process being used. However, Grade 5 and Grade 2 titanium are the most commonly used grades for Swiss machining due to their excellent properties and availability.

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CNC Swiss Machining

CNC Swiss Machining

CNC Swiss machining is a specialized type of precision machining that involves the use of a sliding headstock lathe to produce intricate parts with high accuracy and tight tolerances. This process is particularly well-suited for small, complex parts that require multiple operations to be performed in a single pass. CNC Swiss machining is known for its ability to produce parts with very tight tolerances, high surface finishes, and excellent straightness, roundness, and concentricity. Falcon's Swiss machining technology is widely used in industries such as medical, aerospace, optics, and electronics, machine & equipment, automotive precision machining, where precision and quality are of utmost importance.

What Are the Advantages of CNC Swiss Precision Machining?

High precision and accuracy: CNC Swiss machining equipment uses advanced technology and specialized tools that allow for very tight tolerances, resulting in parts with exceptional precision and accuracy.

Consistency and repeatability: Highly automated lathe, ensuring consistency and repeatability in the manufacturing process, which is critical for high quantities production.

Multi-axis machining: The Swiss lathe has multiple axes that allow for complex geometries and shapes, which is essential for producing intricate parts and components.

Reduced lead time: CNC Swiss turning machining is known for its high efficiency and fast production times, resulting in reduced lead times and faster delivery of parts and components.

Versatility: It can work with a wide range of machining materials, including metals, plastics, and composites, making it ideal for various industries such as aerospace, medical, and automotive.

Cost-effective: CNC Swiss machining is a cost-effective solution for high-volume production runs, as the high level of automation reduces labor costs and minimizes waste.

Why Is It Called Swiss Machine?

The term "Swiss machine" typically refers to a type of precision lathe called a Swiss-type lathe, also known as a Swiss screw machine. This type of lathe was originally developed in Switzerland in the late 19th century for the watchmaking industry, which required very precise and complex parts to be produced in large quantities.

Over time, the use of Swiss-type lathes has expanded beyond the watchmaking industry to many other industries that require high-precision parts, such as medical, automotive, aerospace, optics, and electronics, mechanical micro machining & equipment.

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Brass and Copper Precision Machining

Is Brass Easier to Machine than Copper?

Copper is a soft, malleable metal that is an excellent conductor of electricity and heat, which makes it suitable for use in a wide range of industries, including electronics, aerospace, and automotive.

Brass is an alloy of copper and zinc, and it is often used in Swiss machining because it is relatively easy to machine and has good corrosion resistance. Brass is generally easier to machine than copper in Swiss machining due to its lower hardness and better machinability characteristics.

In Swiss machining, both brass and copper can be turned, drilled, and milled to create complex shapes and features with high precision. The choice of material will depend on the specific requirements of the part being produced, as well as factors such as cost, availability, and compatibility with other components.

Benefits of Precision Swiss Machined Brass and Copper Parts

Brass and copper machining in Swiss machining offers several benefits due to the unique properties of these materials and the capabilities of the Swiss machining process. Here are some advantages of brass and copper machining in Swiss machining:

Excellent Machinability: Brass and copper are known for their excellent machinability, making them ideal for Swiss turn machining. They are softer than many other metals and can be easily shaped, formed, and machined to complex geometries with tight tolerances.

Superior Conductivity: Both brass and copper are highly conductive materials, making them suitable for electrical and thermal applications. In Swiss machining, brass and copper can be precisely machined to create connectors, terminals, electrical contacts, and heat sinks that require excellent electrical and thermal conductivity.

Corrosion Resistance: Brass and copper form protective oxide layers on their surfaces, protecting them from environmental factors and enhancing their durability. Swiss machining can produce components with precise dimensions and smooth surfaces, further improving their resistance to corrosion.

Strength and Durability: Brass and copper are inherently strong and durable materials, making them suitable for various applications. Swiss machining allows for the production of precise and robust components that can withstand high loads, vibrations, and mechanical stresses.

Aesthetic Appeal: Brass and copper have visually appealing appearances. Their warm, attractive colors and ability to be polished, plated, or finished make them desirable for applications that require an aesthetic touch, such as decorative or architectural components.

By leveraging the benefits of brass and copper machining in Swiss machining, Falcon can produce high-quality, precision components that meet stringent requirements in various industries, including automotive, electronics, aerospace, medical, and more.

Falcon Brass and Copper Machined Parts Application

Brass and copper are commonly used materials in Swiss machining due to their excellent machinability and desirable properties. It finds applications in a wide range of industries. Here are some common areas where these parts are used:

Automotive Industry: Brass and copper machined parts are used in various automotive applications, including fuel systems, engine components, electrical connectors, cooling systems, and braking systems.

Electronics and Electrical Industry: Brass and copper machined parts are widely utilized in the electronics and electrical sectors. They are used in connectors, terminals, switches, circuit boards, heat sinks, and electrical contacts. The high electrical and thermal conductivity of brass and copper makes them ideal for efficient and reliable electrical connections.

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Automotive Precision Machining

CNC machining technologies are widely used in the automotive industry to manufacture high-quality automotive parts that are both cost-effective and efficient. With over 28 CNC technologies in use, including 5 axis machining, milling and turning, micro machining, swiss machining, Sinker EDM, and WEDM, Falcon have the capability to produce a wide range of precision parts for the automotive industry.

Our Swiss machining technology is particularly impressive, allowing for uninterrupted mass processing of complex parts. With its power head design, Swiss machining can perform multiple functions simultaneously, such as turning, milling, grinding, reaming, drilling, boring, threading, end face groove cutting, side groove cutting, side milling, and angle drilling. This allows us to manufacture highly accurate composite shaft and fastener automotive parts with maximum production efficiency and cost-effectiveness.

The automotive parts we manufactured are highly favored by wholesalers due to their high-quality and affordable price. At Falcon, we are committed to delivering the best possible value to our customers through cutting-edge technology and exceptional craftsmanship.

Contact us today to learn more about our machining services and how we can help you take your automotive production to the next level.

Precision Machining Services & Capabilities

1. High Volume-Falcon has over 300 pieces of equipment, such as 5-axis machining center, turning and milling center, WEDM, EDM, and Swiss machine. These advanced equipment enable multi-axis machining, allowing for one-time clamping of materials, which eliminates inaccuracies and tolerance errors caused by repeated clamping. This high-volume production strategy ensures efficient manufacturing, reduced production time, and the provision of top-quality, cost-effective components to global automotive customers.

2. High Precision, Safety, and Eco-friendly-We are proud to have achieved ISO13485 certification, demonstrating our commitment to producing high-quality, environmentally-friendly automotive parts. Our state-of-the-art equipment, combined with a skilled engineering team, ensures precision and safety in every product. We are dedicated to meeting the demands of our automotive customers with reliable, efficient, and sustainable solutions.

3. Variety-Falcon is dedicated to delivering superior quality automotive parts that surpass industry benchmarks to worldwide automotive parts distributors. Our range of high-precision parts includes automotive fasteners, new energy battery components, brake systems, transmission shafts, suspension parts, throttle shafts, worm and worm gears, exhaust systems, and other custom parts. We are enthusiastic about partnering with you on your upcoming project and discovering new opportunities for collaboration.

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Precision Aluminum Parts

Aluminum is a popular material for Swiss machining due to its excellent strength-to-weight ratio, corrosion resistance, and versatility. At Falcon, we utilize Swiss type lathes to achieve incredibly precise tolerances and complex shapes. Our aluminum machining services are highly efficient and cost-effective thanks to the use of advanced equipment and the help of an experienced engineer team.

When producing Swiss machined aluminum parts, it is important to choose the right alloy for the specific application, as different aluminum alloys have different properties and characteristics.

Benefits of Swiss Machining Aluminum Parts

Aluminum has a variety of properties and characteristics that make it ideally suited for Swiss machining. The following are some of the biggest advantages of working with this material.

1. Lightweight: Aluminum is a lightweight material, making it ideal for weight reduction is important. Using aluminum in Swiss turning allows for the production of lightweight components in industries such as aerospace, and automotive, improving fuel efficiency and performance.

2. High Machinability: Aluminum has low cutting forces, which result in reduced tool wear and longer tool life. Swiss machining, with its precise control over cutting operations and optimized tool geometries, can efficiently and effectively machine aluminum parts, saving time and cost in the manufacturing process

3. Good Thermal Conductivity: Aluminum has excellent thermal conductivity, which means it can effectively dissipate heat. In applications where heat management is critical, such as heat sinks or electronic enclosures, using aluminum in Swiss machining ensures efficient heat transfer and helps maintain optimal operating temperatures.

4. Corrosion Resistance: Aluminum naturally forms a protective oxide layer on Swiss machined parts' surface, providing inherent corrosion resistance. Swiss machined aluminum parts can withstand corrosion, extending the longevity and reliability of the components

5. Electrical Conductivity: Aluminum exhibits good electrical conductivity, making it suitable for electrical and electronic applications. Swiss machined aluminum parts can be utilized in connectors, terminals, and other components where efficient electrical conductivity is required.

6. Cost-effective: Aluminum is a cost-effective material compared to other metals. It is abundant, readily available, and has a lower material cost. The combination of aluminum's affordability and Swiss machining's efficiency makes it an economical choice for various industries.