10
Mar
Zirconia, with its excellent biocompatibility, corrosion resistance and aesthetic properties, has been widely used in the field of dental implants. However, fully sintered zirconia materials are highly hard and brittle, and during the processing, they are prone to cracking edges, micro-cracks and dimensional fluctuations.
Recently, we have entered into a technical cooperation with a Swiss medical dental implant manufacturer. We have provided them with a complete set of PCD micro tools processing solutions. The customer’s requirements are very typical: small size, ultra-high precision, long life and stable production. The tools involved include: PCD micro-edge milling tools; PCD standard inserts; PCD micro-drills; PCD thread milling tools. This is not a single tool requirement, but an entire chain of micro-precision processing.
Cutting tools: PCD turning inserts (VCGW110302, DCGW11T304, VCGW110301)
Application locations: External cylindrical fine turning; Conical structure processing; Steps and shoulder transitions;
Features: Sharp cutting; Stable edge; Long service life;
PCD inserts are mainly used in the shaping and size control stages, and are a key step for ensuring geometric accuracy.
Tool: Ø2.3mm 18-edge PCD micro-edge milling tools;
Application positions: Arc transition of implant neck, end face and micro step; Outer contour fine finishing; High-precision surface treatment;
Features: Multi-edge structure enhances stability; Low vibration; Excellent surface roughness control; Suitable for non-ferrous metals or high-hardness brittle materials;
The multi-edge PCD structure can achieve very smooth cutting trajectories in a high-speed spindle environment, especially suitable for the consistency control of batch parts.
Tool: Ø1.42mm PCD micro drill (effective processing length 12.5mm)
Application positions: Functional holes; Through holes; Thread bottom holes;
Technical difficulties: Edge chipping at the hole opening; Limited chip removal space; Extremely low tool rigidity; High risk of tool breakage;
The advantages of PCD micro drills are: High wear resistance; High consistency of hole diameter; Suitable for mass production;
Tool: PCD thread milling TOOLS M1.4×0.2 (depth 5.5mm)
Application location: Used for processing the internal connection structure of implants. This already falls under the category of extremely small pitch micro-thread processing.
When machining micro threads in zirconia materials, extremely high requirements are placed on the tool strength and interpolation strategy.
The PCD thread milling tools can significantly improve the tooth shape integrity and tool lifespan.
1. Outer cylindrical turning (PCD inserts)
2. Fine refinement of external contour (18-edge PCD micro milling tools)
3. Internal drilling (Ø1.42 PCD micro drill)
4. Internal thread milling (M1.4×0.2)
5. Final microstructure finishing (possibly still using 18-edge cutting tools)
If you are looking for an overall solution for micro PCD tools, please feel free to discuss the specific conditions with us. We not only offer cutting tools, but also provide feasible processing paths.
