Features down to 50 µm. Tolerances to 2 µm. Precision in miniature.

We define micro machining as operations involving tool diameters below 0.5 mm (500 µm), producing features below 0.1 mm (100 µm). This is a different regime from standard CNC: tools are fragile, cutting forces minimal, and part fixturing critical. We maintain dedicated micro-milling centers with granite bases, air-bearing spindles (180,000 rpm), and high-resolution positioning (0.1 µm increments).

Smallest end mill we stock: 0.05 mm (50 µm). Smallest drilled hole: 0.1 mm (100 µm). Smallest machined slot: 0.08 mm with 0.05 mm end mill. Smallest pocket: 0.2 mm × 0.2 mm × 0.1 mm deep. For features below 50 µm, we transition to laser machining, EDM, or photolithography through specialty partners.

Critical features: ±0.002 mm (2 µm) on dimensions below 10 mm. General micro-machined features: ±0.005 mm. Surface finish Ra 0.2 µm single-pass with 0.1 mm ball end mill. Positional tolerance of 0.01 mm typical. For tighter than ±0.002 mm, post-machining lapping or polishing is needed.

Best: free-machining brass C360 (fastest, cleanest chips), aluminum 6061/7075, stainless 303 and 17-4 PH, Delrin POM, PEEK. Challenging but possible: titanium (slow speeds), Inconel (very slow), hardened tool steels. Poor: sticky materials (copper, pure aluminum) that gum up tiny tools. Material selection affects feature size achievable.

Microfluidics (lab-on-chip, PCR plates), medical devices (stents, suture anchors, surgical tools under 5 mm), watch components (balance springs, pivots), semiconductor test sockets, sensor components (MEMS packaging), precision optics mounts, fiber-optic connectors, and aerospace/defense miniaturized systems.

Yes — per unit volume removed, much more expensive than standard machining. Tool costs are higher (a 0.1 mm end mill costs $50–200 vs $5 for a standard end mill), cycle times are longer (feeds and speeds reduce with tool diameter), and inspection requires specialized equipment. However, for parts with features impossible via other processes, the cost is justified. Typical micro-machined part: $80–500 per piece depending on complexity.