High-tech at the smallest edge

Processes specifically tailored to the handling of micro-tools ensure quality at CemeCon. (Copyright: CemeCon AG)

High-tech at the smallest scale (Copyright: CemeCon AG)

High-tech at the smallest edge (Copyright: CemeCon AG)

High-tech at the smallest scale (Copyright: CemeCon AG)

Miniaturization sets trends – from dental implants to electronic components and watch movements to micro ball bearings. The demand for ever smaller parts leads to increasingly smaller precision tools and tighter tolerances. The consequence: coatings must also meet these developments. It is not only important that the coatings combine minimal layer thickness with outstanding properties, but also that workflows and handling are tailored to tools only a few millimeters or even tenths of millimeters thin. This comprehensive know-how is found in tool manufacturers at CemeCon's coating experts.

When tolerances in the micrometer range must be maintained, there are high demands on process safety, service life, and precision. Ultra-thin and smooth HiPIMS and diamond coatings ensure that micro tools achieve the required performance in everyday machining. And those who have their micro tools coated in one of CemeCon's coating centers can be confident that their mini- and micro-tools are in good hands.

This is made possible by a passion for perfection and attention to detail, reflected in sophisticated work plans. Quality is the sum of many components, and each step is documented. "For handling delicate micro tools, we have developed coordinated workflows, processes, and fixtures to enable employees to work process-safely. Examples include special holders for micro tools during charging or the specially developed cleaning system for steaming out cooling channels. No available system on the market convinced us. Therefore, CemeCon Production Engineering built a system perfectly suited for micro tools. To avoid direct contact with fingers, our colleagues also use tweezers during handling and wear gloves," explains Manfred Weigand, Product Manager Round Tools at CemeCon, about some of the adjustments in CemeCon's production specifically for micro tools.

Especially when coating micro tools, absolute cleanliness is crucial. Even the smallest particles on the tools influence the coating and thus the quality. Therefore, CemeCon places particular emphasis on cleaning: this applies not only to the tools but also to covers, charging materials, and the entire production. A particularly gentle cleaning of the micro tools during pretreatment ensures an excellent coating result. In CemeCon's diamond coating department, there is also another special feature: tools are processed in a cleanroom to protect them from external influences.

Why is CemeCon so good at coating micro tools? CemeCon has over 35 years of experience in coating cutting tools and has specialized exclusively in this. This means all workflows and processes are tailored to precision tools – whether HiPIMS or diamond coatings. This comprehensive know-how in handling tools makes it easier to adapt processes to the "minis." "Furthermore, we started coating small tools very early on – when micro tools were still considered exotic. Sputtering is our technology of choice and is perfectly suited for coating tiny tools – just like HiPIMS, as its further development. The traditional arc process is excluded here. Over many years, we have accumulated experience in this field," adds Manfred Weigand.

HiPIMS and Diamond – Coordinated Coatings for Micro Tools

HiPIMS is perfect for micro tools, says Ramesh Agarwalla, Director at CTC Precision Tools, India, and expert in micro tools for circuit board manufacturing and micro machining tools for dental and medical technology. "Especially with micro tools, defects in the coating – so-called droplets – are fatal because they have an even more extreme impact in these tiny dimensions than with larger tools. Consequently, flawless smoothing is an absolute requirement. That’s why the HiPIMS process – which inherently produces no droplets – is the key to our success!"

Ultrathin HiPIMS coatings reproduce complex tool geometries one-to-one. Christoph Schiffers, Product Manager Technology at CemeCon, explains: "Anyone who wants to reliably and process-safely apply coatings to the delicate geometry of a micro tool needs adjusted residual stresses. Only then can fine cutting geometries be coated uniformly. With our HiPIMS technology, residual stresses can be controlled and significantly reduced – perfect for sharp cutting edges of micro tools."

The highly precise Multilayer CCDia® coatings are ideal for high-end micro tools, such as manufacturing highly complex graphite electrodes or dental implants. Production via the hot filament process ensures thin layers with a homogeneous thickness distribution within tight tolerances – even with complex, delicate geometries. "To ensure the high accuracy of the tools even after coating, we can coat precision tools in the desired final size upon request – and always reproducibly, including documentation," adds Manfred Weigand.