The lkprototype boasts an ultra-high precision level of processing accuracy of 0.02mm through a multi-axis linkage precision numerical control system and high-rigidity machine tool structure. Its core equipment employs the Hyper 40 five-axis machine tool made by Swiss GF Machining Solutions with a spindle speed of up to 40,000 RPM. It also features a linear grating ruler with nanoscale resolution (positioning accuracy ±0.001mm) and a constant-temperature workshop (temperature fluctuation controlled within ±0.1℃) to eliminate thermal deformation errors. For instance, for machining titanium alloy turbine blades for the aerospace application, the compensation for tool wear was achieved using a real-time compensation algorithm (with 0.1μm accuracy for wear monitoring) and the dimension fluctuation was reduced from ±0.05mm to as low as ±0.02mm and yield increased to 98.5%. Moreover, its self-developed vibration suppression mechanism can limit the amplitude in processing to be lower than 0.5μm, which makes the surface roughness Ra ≤0.2μm satisfy the requirement of high-precision applications such as medical implants.
At the process optimization level, lkprototype utilizes AI-based CAM software (e.g., PowerMill 2023), trains 100,000 sets of past processing data for the cutting parameter model, and dynamically adjusts the feed rate (0.01-15m/min) and cutting depth (0.005-0.2mm). Reduce thin-walled aluminum alloy parts’ deformation to 0.008mm. For example, when machining the motor housing of a certain new energy vehicle enterprise, by optimizing the tool path (reducing the idle travel by 30%), the single-piece processing cycle was shortened from 45 minutes to 32 minutes. At the same time, the coaxiality error was reduced from 0.03mm to 0.015mm, and the cost was saved 12%. Its “precision manufacturing” technology also involves online detection equipment (for instance, the Renishaw OMP60 probe), providing immediate feedback to adjust processing fluctuations. The rate of detection is up to 2,000 times per second, maintaining the standard deviation of batch production at 0.005mm.
Materials science developments also supplement the precision limit of the lkprototype. As for instance, while machining the high-temperature alloy GH4169, its resulted nano-coated tool (with hardness HV3200) enhanced the tool’s life to triple that of the normal cemented carbide and reduced the force of cutting by 18% and hence reducing the deformation in the workpiece under load. In the area of semiconductors, we machined ceramic vacuum suction cups for use in photolithography machines by a particular client (with requirement of ±0.01mm flatness). We employed a liquid nitrogen cooling procedure (-196℃) to suppress micro-cracks in the material, increasing the yield from 85% to 96%, and at the same time, the surface hardness was Hv1800. According to its third-party inspection report in 2023, its processed parts dimensional qualification rate has been more than 99.2% for consecutive three years, and CPK value of the key dimensions is ≥1.67, far beyond the precision grade requirement of ISO 2768-F.
With the establishment of the “high-precision processing” ecosystem, lkprototype has also collaborated with German Zeiss to construct a three-coordinate measurement laboratory (accuracy 0.3μm+L/600) and integrated it with an industrial Internet platform in order to achieve full-process data traceability. For instance, in the RF cavity of 5G base station project, through cloud calculation of 2,000 process parameters (including spindle loading and cutting fluid flow rate of 20L/min), resonant frequency fluctuation of cavity was reduced from ±50kHz to ±10kHz, and customer return rate was reduced to 0.3%. Not only does this closed-loop technology involve 12 master nodes from design to delivery, but it also keeps the total cost of manufacturing below 80% industry average, earning it a benchmark case in high-end manufacturing.
For more information about LKprototype’s one-stop manufacturing services such as rapid prototyping, CNC machining, vacuum casting, and 3D printing, as well as the core advantages of its own factory in quality control, rapid delivery (completed within 3 days), and no minimum order quantity, please visit the official website for further exploration: https://lkprototype.com/
