Machining Technology

Creare is advancing the state of the art in machining technology in two primary areas. First, we have developed Novel Processing Methodologies including laser-assisted machining, ultra-precision machining, and high-performance machining for unique, hard-to-machine materials such as ceramics and titanium. Second, we have developed a number of Specialized Machining techniques and processes for fabricating unique components and devices.

Novel Processing Methodologies

We have developed laser-assisted machining techniques at both conventional and ultra-precision scales. In each case, the laser is used to thermally soften the material in advance of machining with a cutting tool, enabling damage-free machining of brittle materials with reduced tool wear and excellent surface quality. We have used this technique to enable the pre-finishing of ceramic parts for optical applications (mirrors and windows) and larger scale ceramic matrix composite parts for aircraft engines.

In the area of high-performance machining, we focus on the development of unique cutting tool cooling technologies that eliminate the need for conventional flood coolants, while significantly enhancing machining performance. In this case, we focus on the indirect cooling of the cutting tool using a very small flow rate of a specialized cryogenic liquid. While the flow rates of cryogen using our approach are approximately 1/100 of conventional coolants, our approach enables a several fold increase in tool life and a doubling (or more) of processing speed. These advancements are critically important for advanced aerospace materials such as titanium and ceramic matrix composites, where long cycle times and high costs represent barriers to high-volume production.

Specialized Machining Techniques

Our development efforts routinely rely on the capabilities of our in-house CNC and precision shop, where we can achieve tolerances down to 2.5 microns (0.0001 inches). For example, we have developed innovative electric discharge machining methods for drilling small holes, slots, and other features with high surface finish. Applications have included orifices for inkjet printheads and specialized heat exchanger plates. The development of these techniques ultimately led to the founding of the Creare spin-off, Mikros Manufacturing

Creare has used laser micromachining for drilling holes and slots at sizes down to 5 microns (0.0002 inches). We developed a custom laser facility to create capillary structures for spacecraft thermal management and power applications, as well as to fabricate nozzles and plates for the generation of fine aerosols.