Manufacturing Technologies

High precision milling

The Kern contract manufacturing offers a μ-precise HSC machining (High Speed Cutting) in air-conditioned rooms for your machining task. With our modern machinery, we implement high-precision contours, free-form geometries and bores with form and position tolerances of up to ±1 μm with process reliability. This means that time-consuming adjustment can be dispensed with when assembling precision assemblies.

The hydrostatic guides of the Kern Micro HD-line guarantee maximum precision and damping with absolute freedom from friction and excel particularly when machining hardened steels or materials that are difficult to machine. Due to the hydrostatics, we achieve extremely high surface qualities and can thus considerably reduce reworking (e.g. polishing).

‍

The features of Kern contract manufacturing for HSC milling and hard milling at a glance:

• μ-accurate manufacturing in air-conditioned rooms
• CAM programming for 3- to 5-axis simultaneous milling
• High Speed Cutting at up to 50,000 rpm
• Hard milling up to 66 HRC with best surface finish because of hydrostatics
• Quality control with 3D-coordinate measuring systems
• Monitoring of serial production by SPC (Statistical Process Control)

Micromilling and microdrilling

Many industries have a growing need for micro parts, be it analytics, medical technology or traditionally the watch industry. Kern contract manufacturing has more than three decades of experience in this field - since the development of the first micro milling machine - and is constantly developing further.

‍

Our micromilling and microdrilling features at a glance:
 

• μ-accurate production of micro-parts and micro-structures in an air-conditioned space
• Use of micro-tools: from drill size Ø 0.03, milling cutter Ø 0.05, tap drill M0.2
• High Speed Cutting at up to 50,000 rpm
• CAM programming for 3- to 5-axis simultaneous milling
• Quality control with 3D-coordinate measuring systems
• Monitoring of serial production by SPC (Statistical Process Control)

Wire and die-sinking EDM

EDM is a non-contact machining process for workpieces with combined requirements that go beyond milling, e.g. for special geometries or material hardnesses. In Kern contract manufacturing, we achieve the same precision for micro parts and micro structures with this technology as with high-precision milling.

In order to meet our high quality standards with consistent excellence, electrodes and microelectrodes for die-sinking EDM are manufactured on our high-precision Kern CNC milling centres and checked with 3-D coordinate measuring machines.

‍Wire eroding in the Kern contract manufacturing:

• High accuracy within +/− 1.5 μm
• Surface quality up to Ra 0.05
• Micro-EDM & fine wire-cut EDM up to Ø 0.03 mm

• Wire EDM with CNC dividing head (rotary axis)

   

CNC die-sinking EDM in the Kern contract manufacturing:

• ‍16-fold electrode changer
• Micro-EDM with a special generator for ultra-fine structures
• Starting hole EDM from Ø 0.23mm to Ø 3mm

Latest machine technology at Kern Microtechnik:
Our new Agie Charmilles Cut 3000 enables tolerances of 1.5 μm on the workpiece as well as surface finishes of up to Ra 0.05. With the twin-wire system (two-wire guide system), we automatically switch from standard wires to fine wires during machining and can realise inner radii of less than 20 μm. Wire diameters range from 0.03 mm to 0.3 mm.

Lapping, polishing and surface grinding

From the in-house production of high-precision Kern machine components, Kern Microtechnik has great know-how in the production of axis components, spindle beds and guide bearings for precision guide systems.

Surface grinding ensures the flatness and parallelism required for contact surfaces with the best surface quality. With our surface grinding machines, we achieve an evenness and parallelism of 2 μm on a surface of 600 x 200 mm in Kern contract manufacturing.

For the highest precision in combined machining of jig grinding and milling in one clamping, we use our hydrostatic Kern Micro HD. We were able to reduce the machining time for grinding prismatic guides in 5 axes by approx. 80 % compared to conventional machining on a surface grinding machine. The accuracy is 2 µm in parallelism and angularity.

Laser marking

Laser marking is carried out using Trumpf equipment – the TruMark 3230 – enabling applications such as micro-marking and the creation of Data Matrix codes on almost any material. Even the highest requirements can be met thanks to cutting-edge technologies like our in-house developed Kern Femto E3 laser processing center. This system is designed for precise laser micro-machining of small workpieces and is capable of processing extremely hard materials such as tungsten carbide.

Laser processing

Kern is setting new standards in ultra-precise material processing with its Femto E3 laser technology. Thanks to ultrashort pulses, the process enables virtually heat-free machining, resulting in perfect contours even for complex geometries.
With our intelligent adaptive machining technology, we automatically compensate for peaks and valleys, achieving reproducible surface qualities – even under the most challenging initial conditions.

• Ideal for high-strength and difficult-to-machine materials such as carbide
• Processing without thermal damage
• Tolerances down to the micrometer range

• Precise microstructures and fine surfaces

   

For components where conventional machining reaches its limits.

Parts cleaning

Cleanliness is a decisive factor for the functionality of modern high‑end components. That is why KERN offers a well‑designed cleaning concept tailored to different industries and requirements. Our range of services extends from manual cleaning baths for individual single‑part treatment to a fully automated cleaning system featuring:

‍The features of Kern contract manufacturing for HSC milling and hard milling at a glance:

• Ultrasonic cleaning
• Vapor degreasing
• Vacuum drying

To ensure process reliability, components can be inspected for contamination using UV light if required. This allows us to ensure that parts are not only clean, but technically clean.

Special solutions

KERN is your partner for components where others have long since given up. Our strength lies in the combination of technical expertise, deep process know-how, and the courage to break new ground.

We develop customized solutions for:
 

• Exceptional and hard-to-machine materials
• Complex, high-precision geometries

• Requirements that fall outside established standards

   

From prototype to series production, we support you from the initial concept through to the finished component. When precision and quality become the decisive factors for success, KERN is the right choice.