Ultrasonic Machining
Ultrasonic machining/milling can be a slow process that requires a high capital cost and skilled labor. It has inherent limitations in pattern size and symmetry, and can cause breakage of parts less than 500µm thick, especially glass. Tool design and fabrication takes time and are costly. And tools need to be replaced after extended use.
Rotary Tooling/Milling - (Handheld and CNC)
Rotary milling requires a significant capital investment and skilled labor is needed for automation. On brittle materials, there is also the potential for uncontrolled chipping or the need for burr removal. Milling of large areas and contoured surfaces is slow and expensive.
Laser
Laser processes also require a large capital investment. Material removal rates are typically slow especially for large areas. There is more potential for laser/raster marks and micro-cracking.
Electric Discharge Machining (EDM)
Electric discharge machining can only be used with conductive materials. Cutting is slow and can create micro-pitting. EDM can be automated but needs CNC programming and skilled labor. Also, this process requires a very large capital investment. The tooling can be expensive and needs replacing with wear.
Grinding
It is difficult to isolate area of material removal and therefore patterning of surfaces is limited. There is the potential for uncontrolled chipping. It is also a slow process. |
