Hybrid Tooling: A Review of Process Chains for Tooling Microfabrication within 4M

Sabino Azcarate, Luis Uriarte, Samuel Bigot, Pieter Jan Bolt, Lutz Staemmler, Guido Tosello, Stephan Roth, Andreas Schoth

    Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review


    The current paper is based on the information gathered by the “Processing of Polymers” Division (Task 4.2 “Hybrid Tooling”) and “Processing of Metals” Division (Task 7.2 “Tooling”) within 4M Network activities. The aim of the task involves a systematic analysis of the partners’ expertise in different technologies for processing tooling inserts for further replication in polymers. Firstly, the 4M partners current capabilities in individual tooling processes is briefly presented, and also the expected capabilities for year 2010 are analysed for each of the following processes: micromilling, microwire electrodischarge machining (µWEDM), micro sinking electrodischarge machining (µSEDM), laser micromachining, electrochemical micromilling (µECM), and electrochemical milling with ultrashort pulses (ECF). Later the concept of ‘hybrid tooling’ as different process chains for tooling fabrication is introduced. Several examples of ‘hybrid tooling’ within 4M partners are presented. Considered materials are nickel for electroforming, stainless steel for ECF, and tool steel for the other processes. The paper results provide a global comparison between the previously mentioned processes, the current limitations of these technologies concerning feature sizes, surface finish, aspect ratios, etc. have been identified. The main conclusion drawn is the imperative requirement to combine individual processes (‘hybrid tooling’) to produce mould inserts required outside research laboratories.
    Original languageEnglish
    Title of host publicationProceedings of 2nd International Conference on Multi-Material Micro Manufacture (4M)
    Number of pages410
    Place of PublicationGreat Britain
    Publication date2006
    ISBN (Print)00-80-45263-0
    Publication statusPublished - 2006
    Event2nd International Conference on Multi-Material Micro Manufacturing - Grenoble, France
    Duration: 20 Sep 200622 Sep 2006
    Conference number: 2


    Conference2nd International Conference on Multi-Material Micro Manufacturing
    Internet address

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