August 30, 2024
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Figure 1: INSACO has been a precision machining and polishing company for parts from all technical ceramics, sapphire, glass and quartz. Source: INSACO
Since 1947, INSACO has been a precision machining and polishing company for parts from all technical ceramics, sapphire, glass and quartz. They machine these materials while holding very precise tolerances — often holding tolerances as tight as ± .0000393 inches (± 0.001 mm) — for properties such as overall geometric dimensions, flatness, wedge, roundness or cylindricity among others. Customers typically have a critical application that requires extremely tight tolerances in ultra-hard materials. Typical use cases include utilizing the material’s high hardness for increased durability and lifetime of the part in critical applications.
Features include:
- Extremely high accuracy and tight tolerance machining
- Lights-out manufacturing
- Machine automation including large capacity envelope
- Automated centerless grinding
- High efficiency, low-cost volume production
- Low-volume prototype machining
- Five-axis machining capability
- ITAR certified
- ISO 9001 Compliant
- Robotic machining
- Video inspection and a Class 100 cleanroom
- Extensive quality control protocols
INSACO also has extensive inspection and documentation procedures to ensure parts are made to print. Their engineering team is available to discuss any application needs, including alternative materials and cost drivers.
Typical applications for ceramics (carbides, nitrides, sapphire, glass, quartz/fused silica, etc.):
• Guidance systems components
• Microwave tubes
• Mass spectrometer/RGA components
• Heart pump components
• Vacuum instrumentation devices
• Infrared optical parts
• Ceramic components for oil field systems
• Sapphire detector tubes for high pressure liquid chromatography
• Titanium carbide disks for ultrasonic transducers
• Laser gyro systems
• Tape transfer systems
• Infrared detectors
• Photomultiplier windows
• Fiber optic devices
• Mass spectrometer quad holders
• Fluid metering parts
• Check valves
• Sapphire wafer carriers
What tolerances can INSACO hold?
The nature of diamond grinding on ultra-hard materials translates into routinely achieving tight tolerances.
Figure 2: INSACO focuses solely on machining and does not produce any materials. Source: INSACO The actual limits to the attained precision depend on variables like the machine tool used, the general shape and size of the part and the sequence of operations needed to complete the task. Although the standard for machining is +/-0.004 inches, INSACO generally halves this on the first pass of operations. Secondary operations can further narrow this to +/-0.0001 inches. The flat lapping operations can best be recorded in millionths of an inch. Previous bearing parts have reached tolerances in the millionths of an inch. Regardless of desired tolerances, INSACO can offer expert feedback about practical limitations and cost considerations.
Strict material considerations
INSACO focuses solely on machining and does not produce any materials.
Alumina is the most common technical ceramic and hence most readily available and usually lowest cost. Properties of alumina are exceptional in many ways when compared to conventional materials like steel. If the use conditions exceed these properties, other technical ceramics — though less common — such as silicon carbide or zirconia may be better choices.
Figure 3: INSACO utilizes a variety of criteria to make material suggestions. Source: INSACO
INSACO utilizes a variety of criteria to make material suggestions, including the customer’s application requirements, physical and thermal properties, cost, machinability, wear resistance and any other unique requirements by the customer. Also taken into consideration is the availability of the material, current manufacturing capabilities, cost parameters and the production lead time required for specific parts.
Figure 4: INSACO has built a reputation in providing expertise in the precision machining of ultrahard materials for all customers. Source: INSACO
INSACO has built a reputation in providing expertise in the precision machining of ultrahard materials for all customers. They recognize that their most important asset is the customer, which is why they make it a point to keep the customer first in everything they do. Customers that need a quality, high precision machined part from hard materials should contact INSACO.
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