Micro tool design and fabrication: a review

Mechanical micromachining is considered as a cost-effective and efficient fabrication technique to produce three dimensional features and free-form surfaces from various engineering materials. Micro cutting tools are an essential part of mechanical micromachining and they are exposed to harsh conditions which reduces tool life and adversely affect the economics of the process. The challenge is therefore to maintain the tool rigidity and cutting edge sharpness for extended period of time. Thus, the design, fabrication and durability of micro cutting tools are of significant importance for successful micromachining operations. This review paper aims to provide a comprehensive understanding about the capabilities, characteristics, and limitations of different fabrication techniques used in the manufacturing of micro cutting tools. State-of-the-art micro cutting tool design and coating technology has been presented for various micromachining applications. Possible future research direction and development in the field of micro tool design and fabrication has also been discussed.