State-of-the-art femtosecond laser technology forms the basis for the manufacture of micro-PKD drills. This technology enables extremely hard materials such as PKD and CBN to be machined with the utmost precision and with virtually no thermal influence. This makes tool geometries possible that would be difficult or impossible to achieve using conventional grinding methods. This opens up new possibilities, particularly in the micro-scale, as the tool geometry is no longer limited by the shape of the grinding wheel.

Whilst solid carbide tools have predominantly been used in micro-machining to date, ZECHA’s new laser technology enables the cost-effective machining of PCD and CBN materials at the micro-scale for the first time. This results in micro-PCD drills with diameters of up to 50 µm, whose laser-generated cutting contours enable reduced cutting forces, optimised chip evacuation and significantly longer tool life during the drilling process. For users, this means greater process reliability, fewer tool changes and consistent machining quality, even in particularly intricate applications.

The new micro-PKD drills are used, amongst other things, in medical technology, precision engineering, the semiconductor industry, and in the jewellery and watchmaking industries for machining non-ferrous materials. It is precisely where the smallest structures, tight tolerances and high-quality surfaces are required that these new tools really come into their own.

A key factor in their success lies in the interplay between laser technology, specialist process know-how and precisely engineered tool geometry. Parameters such as pulse duration, energy input, focal position and machining strategy must be precisely coordinated to produce high-precision cutting edges and micro-geometries. At the same time, the use of PCD as the cutting material creates ideal conditions for applications involving demanding materials, as polycrystalline diamond offers exceptional hardness, wear resistance and thermal stability.

In addition to its technical capabilities, the new manufacturing technology also contributes to greater resource efficiency. Compared with conventional grinding processes, there is no need for grinding wheels, grinding oil, filter systems or time-consuming processing procedures. The ultra-short-pulse femtosecond laser used operates with extremely short pulses in the range of 10⁻¹⁵ seconds and enables virtually heat-free material machining. This conserves resources, reduces maintenance requirements and lowers production overheads.

With the micro-PKD drill bit, ZECHA underlines its technological expertise in precision and micro-machining. More than 15 years of research and development in the field of laser technology and process development form the basis for a tooling solution that combines the highest precision, long tool life and reliable performance. ZECHA is thus setting new standards for the cost-effective machining of the most demanding micro-applications and strengthening its position as an innovation partner for international future markets.