son-x is a leading edge technology and component supplier in the field of ultra precision machining. The UTS technology developed and commercialized by son-x enables direct machining of steel with single crystal diamond tools.
Main applications are optical mould inserts for injection moulding in LED lighting.
Benefits of the technology: Direct diamond machining of steel; No nickel plating; Faster manufacturing; Less costs
Benefits of the Mould Inserts: Monolithic stainless steel inserts (no coating); Longer insert life; Faster manufacturing; Scratch resistant inserts; Quick repairing
On the LASER World of PHOTONICS CHINA the second generation equipment “UTS2” with a unique frequency of 100 kHz is presented. Mould insert examples, plastic lens prototypes and mirrors are displayed.
son-x has two business fields:
Ultrasonic tooling system - UTS2
The UTS technology developed and commercialized by son-x enables direct machining of stainless steel with single crystal diamond tools. A consistent surface quality of Ra=3nm and a form accuracy of 150 nm can be achieved.
Benefits of the technology: Direct diamond machining of optical mould inserts in steel; No nickel plating; Faster manufacturing; Less costs; Higher part durability; Quick repairing.
Optical mould inserts directly in steel
With our long term experience in ultra precision technology and our sophisticated equipment we offer contract based manufacturing of of optical mould inserts, plastic lens prototypes (PMMA, PC) and other optical precision parts.
Our main applications are steel mould inserts for injection moulding of optics for automotive lighting, LED illumination and imaging/camera lenses.
The established 100-kHz Ultrasonic Tooling System UTS2 developed by the company son-x enables direct ultra-precision machining of stainless steel with single crystal diamond tools and with maximum efficiency. There is almost no geometric constraint towards the machined geometry. The UTS2 operates with a unique frequency of 100 kHz enhancing cost effectiveness with ultra precision.
The so called ultrasonic assisted process enables direct cutting of stainless steel with diamond tools, without the need of a nickel plating. In fact, this technology is available on the market since 2011 from son-x. Now the second product generation in ultrasonic tooling systems is introduced, the UTS2, which has a frequency of 100 kHz and no constraints towards the machinable geometry.
During the process the diamond tool oscillates in a linear motion generating an intermitted cutting condition with 100.000 contacts per second. This leads to a better cooling of the diamond as well as a suppression of the chemical interaction between the iron and the carbon in the diamond, which results in a significant wear reduction. A consistent surface quality of Ra=3nm and a form accuracy of PV
Due to its compact design the UTS2 can be integrated into commercially available precision and ultra precision machine. For machines without a vertical axis a micro height adjustment is foreseen. The simple and clear handling of the system based on the “Plug&Play” principle ensures an immediate and efficient use of the technology. The required diamond tools are not limited with regards to their geometry and can be purchased at commercial vendors.
The typical application of this technology is mould insert manufacturing for plastic injection moulding. Steel inserts have a higher tool life and can be manufactured quicker with the UTS2 technology. The inserts are more scratch resistant than nickel plated or aluminum inserts and can be repaired quickly, if damaged. The technology makes mould manufacturing quicker and injection moulding of optics more efficient. (www.son-x.com)
The unit as well as optical mould inserts are displayed at our booth.
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