Loving this forum!
I am working on a research project that involves "glue-ing" carbon-based nanotubes (well, closer to microtubes) into channels etched into various aluminum, nickel, and anodized aluminum alloys. The scale of the tubes are 50 um (0.001968503935 inches to be kinda precise). However, the profile of the tubes are more rectangular with dimensions of 50um x 10mm x 500um with spacing of 50um. It is possible that some samples will be made with larger tubes of 200um x 10mm x 800um with 100um spacing. The "glue" is more complex than super-glue or other ethyl cyanoacrylate-based adhesives but need not be taken into serious consideration as the glue we developed adds only 1.1 um to each surface when cured. Interestingly enough, it is possible that one application of this product would be for micro-friction/air bearing rails.
What would you recommend as a setup/manufacturer for a CNC machine? The samples range from 2x2 in to 8x4 in. I have no idea where to start for tooling, bits etc. The depth of 500 um is little more than a scratch, but some of the alloys are tough. Are there bits this fine (or finer)? If I make a scratch, how can I efficiently deburr the edges without rounding them back into the voids?
I'm not looking for a big bed, not looking for high inches per second, but the number one criterion is high accuracy with high repeatability (and the tooling and bits to go with it). We created some samples with diamond "chips" embedded in a modified hand planer...so you can see that is not exactly accurate or repeatable. It was only a test : )
Thanks a bunch!