Performance Micro Tool's Unprecedented Advancements in End Mills and Cutting-Edge Applications3/13/2024 Performance Micro Tool first to make the world's first 5 micron end mill.  Performance Micro Tool 50 μm drill shown next to ant leg. Photo courtesy of Texas A&M University Today, Performance Micro Tool end mills are approaching diameters and tolerances thought impossible just a few years ago. Their unique manufacturing ability has led to many firsts including the world's first 5 micron end mill. PMT's in-stock and custom end mills are used in some amazing applications - from designing medical diagnostic tools for use inside the body to developing micro components for U.S. fighter jets. The PMT product line and unique quality controls assure customers of superior end mill performance and longevity. They also offer the shortest lead times in the industry! PMT Features
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Stable and high efficiency in small diameter deep-hole applications. by Hiroyuki Amano, OSG Corporation Applications Engineer (Drill Development Division)  OSG Corporation has recently released the ADO-MICRO – the company’s first small diameter carbide drill with oil holes designed for stable and high efficiency drilling in deep-hole applications. The sense of size upon hearing the phrase “small diameter” will be understood differently among users in the manufacturing industry. The ADO-MICRO has a lineup of drill diameters from 0.7 mm up to 2 mm for drill lengths of 2xD and 5xD, and diameter 1 mm to 2 mm for drill lengths of 12xD, 20xD and 30xD. The product name ADO-MICRO may seem to be associated with the unit prefix micro (µ), but it was named to simply imply smallness in size regardless of the unit. For small diameter drilling, options such as carbide drills and HSS drills using external coolant are available. However, today’s machining needs require greater stability, higher efficiency and longer life than ever before. There is no exception in small diameter deep-hole applications, with growing needs for coolant-through small diameter drills. Tool Geometry Figure 1: Chips generated at the tip of the tool flow in the direction of the blue arrow One of the keys for successful small diameter drilling is trouble-free chip evacuation. As illustrated in figure 1, chips generated at the tip of the tool flow in the direction of the blue arrow. However, if there is insufficient space in the flute, cutting chips cannot evacuate smoothly, which causes the drilling accuracy to deteriorate and increases the probability of tool breakage. Therefore, by providing a wider flute specification at the area where the tip of the blue arrow locates, as depicted in figure 1, cutting chips are able to be discharged without difficulty, leading to stable machining.
However, micro sludges can be easily accumulated around the outer periphery of the cutting tool, which is a key cause of abrupt tool breakage. To resolve this challenge and to achieve an overall balance, an extended flute configuration is incorporated to provide sufficient exit room as shown in figure 3. Figure 3. Exit room at end of margin Oil HolesThe ADO-MICRO features a straight hollow shank design where coolant is injected in addition to the two spiral oil hole paths. This configuration increases coolant discharge from the tool tip. Without the hollow shank configuration, greater pressure is required in order for the coolant to pass through the thin oil hole paths. With the hollow shank feature, pressure loss is reduced, which increases the coolant flow volume. As illustrated in figure 4, with a higher coolant flow rate, cutting chips can be more effectively evacuated, thereby enabling stable machining.  Figure 4: Relationship between shank structure and coolant flow volume OSG’s Latest Coating Technology: IchAda CoatingAnother key element for achieving stable processing in small diameter deep-hole application is coating technology. The role of tool coating is to provide wear resistance and heat resistance to prolong tool life, which is particularly important to small diameter tooling. As illustrated in figure 5, the coating surface by conventional technology is not smooth, which may interfere with the performance of chip evacuation. OSG’s latest IchAda coating, on the other hand, provides excellent surface smoothness in conjunction with high wear resistance and heat resistance to enable small diameter tools to achieve long tool life by improving adhesion.  Figure 5: Surface of coating Cutting DataFigure 6 demonstrates a comparison of tool life between the ADO-MICRO and two other tooling manufacturers’ products in the machining of SCM440. The competitor drills have chipped or have broken at the initial machining stage. The ADO-MICRO, on the other hand, was able to achieve long tool life stably due to its superior chip evacuation capability by breaking chips into small and manageable pieces.  Figure 6: Stable and long tool life in SCM440 The ADO-MICRO demonstrates stable performance even in difficult-to-machine titanium alloy applications. As shown in figure 7, the competitor drill struggled with chip evacuation, thus requiring step processing. However, with the ADO-MICRO, step processing can be eliminated while achieving approximately five times the drilling efficiency. The ADO-MICRO was still in good shape after doubling the competitor drill’s tool life, allowing it to be used on other applications.  Figure 7: Efficiency improvement in titanium alloy The ADO-MICRO’s unique tool geometry and OSG’s original IchAda coating allow non-step drilling even for deep-hole applications, enabling high processing efficiency.
By eliminating common complication in small diameter deep-hole drilling, the ADO-MICRO is able to excel with stable performance in a wide range of work materials including stainless steel. In addition to standard stock items, OSG also offers customization services with tailored solutions for each and every manufacturer’s specific machining needs. Hoffman Estates, IL – BIG KAISER, a global leader in premium high-precision tooling systems and solutions for the metalworking industries, announces the MEGA Micro Coolant Nut, a solution developed to provide precise coolant supply to micro cutting tool applications at high speeds.  Efficient coolant delivery prevents chip jamming, which can cause machine stoppages, service calls, and increase tool wear and poor surface finish. As spindle speeds continue to increase, getting the coolant to the cutting tip has become more challenging.
Exclusively for MEGA Micro Chuck 6S, the MEGA Micro Coolant Nut is an ideal design for high-speed micro machining up to Ø6 mm. By using it instead of a standard nut, tool lifetime is increased by about 35 percent and better cutting performance is achieved for milling applications. The MEGA Micro Coolant Nut is a continuation of BIG KAISER's efforts to drive coolant toward the cutting edge and help to maintain process security. For coolant through drills, BIG KAISER offers the MEGA Micro Perfect Seal Nut. If coolant is required, it should be optimized to maximize its true potential. For more information please contact us! This article originally appeared in the Gazette Xtra and I thought it had some great information to pass along to everyone to give you some background on Performance Micro Tool JANESVILLE — As a small Janesville manufacturer, Performance Micro Tool likes to fly under the radar.
Performance Micro Tool's tools have been used to route communications equipment on the Mars Rover project, cut mother of pearl dots on the frets of Gibson guitars and make a harness for a fruit fly. Its tools cut the "plus" and "minus" signs on the sides of 4 million iPhone 4s. Burton said his company prefers a low profile, primarily to keep competitors off guard. That, however, is becoming more difficult. The Wisconsin Entrepreneurs' Network recently named Performance Micro Tool as one of 33 "Wisconsin Companies to Watch." The annual program recognizes companies that demonstrate high performance in the marketplace and exhibit innovative products, services or processes. Performance Micro Tool got its start after Burton watched a progression of big companies pass along ownership of a Janesville facility. The companies started with International Carbide and ended with Kennametal, a huge company with more than 100 facilities. "We were always owned by some out-of-state manufacturer, and in the public sector, the mantra is always the next quarter," Burton said. Kennametal ultimately closed its Janesville shop and shipped the work to a plant in China. Burton and his partner launched Performance Micro Tool. Kennametal soon found that its China plant couldn't do what Performance Micro Tool did, and Kennametal became one of Burton's largest customers. The 12 employees of Performance Micro Tool work across three shifts in a shop on Kennedy Road on Janesville's north side. Machines that robotically grind the tools fill the shop.
"Making them small is certainly our niche," Burton said. "We also do a lot of private labeling, which helps keep competitors off our backs. "We try to keep our prices pretty low to keep competitors from getting into the business and keep them buying from us." Burton credits the company's steady growth to a stable group of dedicated, talented employees, many of who have been with him for years. "These guys will take a bullet for me and this company," he said. "We have an open shop. We're pretty lax and encourage creativity and playing around." Burton said the company pays high wages, covers 100 percent of its health care plan, provides a 401(k) match and often gives bonuses that have included companywide cruises, trips to Cancun and last year involved a Packer-Viking weekend in Minneapolis. "These guys are really concerned about the health of the company," Burton said. "I give them a bonus, and they ask me if I'm sure. "If I wasn't sure, I wouldn't do it. When times are good, we share." Times have been good. A look at the company's growth chart shows a steadily increasing line offset by routine ups and downs. Burton doesn't want to see his company grow too quickly. He knows that fast ups can create fast downs. "If we were to double in size next year, our customer base would suffer, no doubt," he said. In 2009, Performance Micro Tool's sales were off 15 percent when its competitors experienced declines of 45 percent to 60 percent.
"I might tell a customer it will be three days, but my guy on the floor will look at it and say 'I'm gonna knock this out in one day because there's potential here,'" Burton said.
Performance Micro Tool is the definition of innovation, said Phil Jackson, the Wisconsin Entrepreneurs' Network regional director who nominated the company for the award. "These guys are doing cutting-edge work, no pun intended," Jackson said. "And they're not just sitting here in Janesville looking at U.S. markets. They're looking internationally."   Next Generation Tooling is very proud to welcome Performance Micro Tool to our specialized family of CNC products! PMT is a high technology micro carbide tool company that specializes in real world customer performance with results gained through both superior manufacturing processes and second-to-none customer service. It's performance you can measure in microns – and in years. Performance Micro Tool IS the world leader in micro end mills and other micro tools. They have over 30 years of experience in micro engineering, design, and manufacturing. They where the first and only company that to develop a 5 μm end mill!
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NEWSOur NEWS blog section is written by several different people. Sometimes, it from our team here at Next Generation Tooling & at other times it's by one of the manufacturer's we represent. 
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