Industrial measurement and optical instrumentation systems frequently rely on specialized guide bushings and segments containing microscopic, highly accurate bores. These holes serve as alignment pathways for fiber-optic cables or miniature sensor probes, demanding diameter accuracy within microns and a mirror-like internal surface finish. Machining holes with diameters below 0.50 mm using traditional mechanical drills is highly inefficient, frequently resulting in broken tools, tapered holes, and excessive burrs at the exit point.
To overcome these limitations, the company utilized its high-precision wire EDM machinery capable of running specialized fine-wire setups. The segments were pre-drilled with starting holes before being transferred to the EDM unit, where a microscopic wire eroded the final bore geometry. The power supply parameters were adjusted to generate spark frequencies that yielded an ultra-smooth internal surface finish of 0.2 µm Ra, maintaining total cylindricity and eliminating exit burrs.
Metrological sampling confirmed that the internal diameters-including the critical 0.42 mm and 0.49 mm bore series-met the required micron-level tolerances. The segments provided smooth friction-free pass-through for the client’s fiber-optic assemblies, eliminating assembly reject rates entirely. This capability emphasizes the company's specialization in micro-machining challenges that lie beyond the boundaries of standard CNC milling.
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