Design for next generation fuel injectors could not be realized due to lack of existing high precision micro hole drilling solutions.
Integrated athermal laser micro machining, multi-axis scanning and rapid part handling.
Design specs achieved and cycle time requirements met. Multiple precision micro hole drilling solutions working in factories worldwide.
Today, because of government fuel efficiency mandates and consumer demand for better mileage, the auto industry is under pressure to deliver more efficient vehicles.
A global tier 1 auto parts manufacturer had designed a next generation fuel injector that could more precisely vaporize fuel to get more combustion from less fuel – dramatically improving auto fuel efficiency. The design required ultra precise holes to be drilled into the injector head; holes that would ensure extremely accurate fuel delivery. The problem was that no existing micro drilling technology was able to achieve the dimensions and surface quality needed to get the design into production.
The company turned to Microlution’s ultra precise micro hole solution. Based on the ML-5 platform, the solution integrates a state of the art femtosecond laser. Femtosecond lasers remove material without heat, allowing for accuracy not possible with any other technology, and eliminate thermal defects that would otherwise compromise part quality. Because the laser tool does not degrade over time like a mechanical tool, the solution features dramatically improved part consistency and cycle times. The solution also features a high speed, multi-axis scanner to move the laser beam in multiple directions and angles, and the ML-5’s micron-level positional accuracy. The solution delivers micro holes with unprecedented surface, quality and edge quality, along with the flexibility to create holes with different shapes and tapers and to drill virtually any material.
For the tier 1 auto parts manufacturer, the result is a complete micro hole drilling solution that creates the exact hole dimensions required for round, elliptical, tapered and non tapered holes. The solution is now at work 24/7 in their factories around the world, enabling faster production, higher quality parts, and better fuel efficiency.