This study describes the use of micro electro-discharge machining (m-EDM) scanning technology to fabricate micro three-dimensional cavities and microtools fabrication on polycrystalline diamonds (PCD). The experimental results show that short-pulse discharge from an resistor-capacitor (RC) circuit is more effective and precise than a transistor (Tr) pulse generator while machining PCDs by m-EDM. The surface roughness of PCD using the m-EDM scanning process could be as small as Ra 0.2 mm, even when the diamond grain size is considerably larger. Moreover, small PCD tools for cutting brittle materials could be easily fabricated by the same m-EDM process. Thanks to their hardness and excellent thermal conductivity, PCDs could be utilized in the near future, not only for micro molds, but also for tools to cut brittle material.

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This article describes a hybrid gluing and assembling approach on micro-electrodischarge machining (EDM) to fabricate microglass spherical stylus tips for microcoordinate measurement machines (CMM) probing heads. Combining wire electrodischarge grinding (WEDG) technology and position controlling function of EDM, a microglass ball could be glued onto the front-top of the microtool successfully. Photo images and adhesion strength measurements were carried out to evaluate the gluing quality of the glass ball-ended stylus tips. The experimental results show that deviation of the largest profile of micro-stylus tips with a 0.07 mm diameter could be as small as 1.53 mm, and the adhesion strength is approximately 12 mN without any detachment or bending. With further improvements of epoxy glue materials, this assembling process on micro-EDM will be a new approach to fabricate microspherical stylus tips for micro-CMMs probing heads.