Micro-Manufacturing and Applications, 5th Edition: Materials and High-Precision Micromachining

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D:Materials and Processing".

Deadline for manuscript submissions: 30 August 2025 | Viewed by 1121

Special Issue Editor

Special Issue Information

Dear Colleagues,

Micro-machining became fashionable more than 15 years ago as the need for micro-parts became dominant in consumer and military markets. In the beginning, a significant portion of micro-parts were made of silicon, it being one of the most well-known materials. The processing technologies also came from the semiconductor industry, and the equipment as well machines predominantly primarily concerned the production of silicon-based parts. This material could not, however, meet the need for micro-parts and products for the market. There was and still is significant demand for non-silicon-based micro- and nano-products, as well as for the development of processing equipment and machines for non-silicon-based materials. It has thus become clear that the materials used in normal manufacturing are in most cases not applicable or suitable for the production of micro- and nano-parts. It has also become clear that the existing manufacturing technologies can, to some extent, be scaled-down, but there are natural limits to the equipment and processes beyond which new technologies (processing windows) and equipment need to be designed and adopted. In many cases, specific manufacturing processes are oriented toward specific materials, and the production of specific parts (or features) is only possible with the use of certain technologies.

The aim of this Special Issue is to publish papers devoted to materials and specific micro/nano-manufacturing technologies. Also welcome are papers devoted to designing materials with pre-defined properties (either for specific processes or specific uses). It is anticipated that the need to design materials for specific needs will grow rapidly; thus, establishing standards for micro/nano-machining is important. This being the case, papers focusing on establishing the natural boundaries of processes and/or determining their limits are very welcome.

Dr. Atanas Ivanov
Guest Editor

Manuscript Submission Information

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Keywords

  • micro manufacturing
  • high-precision micromachining
  • specific micro/nano-manufacturing technologies
  • materials design
  • micro/nano-machining

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Published Papers (2 papers)

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Research

12 pages, 1408 KiB  
Article
Advanced MMC-Based Hydrostatic Bearings for Enhanced Linear Motion in Ultraprecision and Micromachining Applications
by Ali Khaghani, Atanas Ivanov and Mina Mortazavi
Micromachines 2025, 16(5), 499; https://doi.org/10.3390/mi16050499 - 24 Apr 2025
Viewed by 205
Abstract
This study investigates the impact of material selection on the performance of linear slideways in ultraprecision machines used for freeform surface machining. The primary objective is to address challenges related to load-bearing capacity and limited bandwidth in slow tool servo (STS) techniques. Multi-body [...] Read more.
This study investigates the impact of material selection on the performance of linear slideways in ultraprecision machines used for freeform surface machining. The primary objective is to address challenges related to load-bearing capacity and limited bandwidth in slow tool servo (STS) techniques. Multi-body dynamic (MBD) simulations are conducted to evaluate the performance of two materials, alloy steel and metal matrix composite (MMC), within the linear slideway system. Key performance parameters, including acceleration, velocity, and displacement, are analyzed to compare the two materials. The findings reveal that MMC outperforms alloy steel in acceleration, velocity, and displacement, demonstrating faster response times and greater linear displacement, which enhances the capabilities of STS-based ultraprecision machining. This study highlights the potential of utilizing lightweight materials, such as MMC, to optimize the performance and efficiency of linear slideways in precision engineering applications. Full article
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18 pages, 11650 KiB  
Article
Optimization of Cutting Parameters to Minimize Wall Deformation in Micro-Milling of Thin-Wall Geometries
by Ahmet Hasçelik, Kubilay Aslantas and Bekir Yalçın
Micromachines 2025, 16(3), 310; https://doi.org/10.3390/mi16030310 - 6 Mar 2025
Viewed by 626
Abstract
Thin-walled micro-structures are a critical component of micro-devices, and their precise manufacture has a direct impact on product performance. Micro-milling is an effective manufacturing method that enables the production of micro-thin-walled structures with high precision and performance. Wall deformation is an undesirable problem [...] Read more.
Thin-walled micro-structures are a critical component of micro-devices, and their precise manufacture has a direct impact on product performance. Micro-milling is an effective manufacturing method that enables the production of micro-thin-walled structures with high precision and performance. Wall deformation is an undesirable problem in the production of parts with complex geometries and high aspect ratios, particularly when the height-to-thickness ratio (h/t) exceeds 20. In the micro-milling process, cutting parameters are the main factors affecting wall deformation. Therefore, optimising the cutting parameters is critical for the accuracy and precision of the cutting process. In this study, thin walls of 50 µm thickness, 1 mm height and 10 mm length were machined from an Al6061-T6 alloy using a tungsten carbide cutting tool with a diameter of 1 mm. The effects of feed rate, spindle speed and depth of cut cutting parameters (control parameters) used in the micro-milling process on the cutting forces and wall deformation (outputs) were investigated. A Taguchi L18 orthogonal design was used to optimise the cutting parameters. During the micro-milling experiments, the cutting forces were recorded, and the amount of deformation occurring in the thin wall was accurately determined using an optical profilometer with a motorised measuring system. Taguchi and ANOVA analyses were performed on the measured values of Fx tangential force, Fy feed force and thin-wall deformation to determine the effect of the control parameters on the outputs and to determine the most suitable cutting parameters to minimise deformation and keep the cutting forces under control. As a result of this study, the cutting parameter with the highest effect on the tangential force Fx was the depth of cut, with 56.94%, while the most effective cutting parameter on the feed force Fy was the feed rate, with 45.3%. The most effective parameter on the machined thin-wall deformation was the feed rate, with 87.36%. This study on the optimisation of cutting parameters in micro-thin-walled structures covers a unique topic that has been addressed in limited numbers in the literature. Full article
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