IKONICS Corporation

Precision Abrasive Machining

Through processes based in photochemistry, abrasive etching, chemical etching and other technologies, IKONICS participates in a diverse spectrum of markets. From traditional and high-tech screen printing, to decorative and industrial etching.

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1 IKONICS Advanced Material Solutions PRECISION ABRASIVE MACHINING TECHNOLOGY (Perforating Composite Materials) Precision Abrasive Machining (PAM) is state-of-the-art technology for producing a variety of features/ shapes and/or perforations in brittle/challenging materials such as, but not limited to composites and semi-conductor wafers, while ensuring low stress impartation and minimizing compromises to the substrates. The advent of Precision Abrasive Machining (PAM) from IKONICS overcomes many disadvantages associated with conventional methods used to perforate composite materials such as eliminating: Drill bit wear/tearing and exit hole burrs due to mechanical drilling (heat build-up) Stresses that can cause internal (unseen) delamination & damage with mechanical drilling Burnishing and distortions from laser drilling (where delamination often occurs) Layer delamination associated with Water-Jet processes (wet process) IKONICS PAM production is done in-house using proprietary and patented technologies. Perforations can be virtually any shape, such as round holes, squares, ovals, or slots in composite materials (including Kevlar®). It does so with high precision and repeatability (to within 50µm) without inducing the stresses and defects associated with conventional machining processes. The resulting perforations have clean edges (no burrs or fibers to remove). MISTRAS (independent composite testing lab) confirms stresses and internal damage are significantly minimized with PAM vs. mechanical drilling. See page 6 for the full report. Laser Drilling – Entry side shows burn marks around the edges. Exit side is also burned on the edges and shows delamination of layers. Heat is generated as a result of the laser process. Water-Jet – Both hole entry and exit show signs of layer delamination. Water-Jet is not very precise (size and location) and can only perforate round holes. PAM Process – Clean entry and exit. No burrs or fibers. This could easily have been oval shapes, squares, slots, etc. Process is 100% dry. "After a series of non-invasive Ultrasonic test scans to check for surface and internal defects (such as delamination), it was clear the IKONICS PAM processed panels had overall less damage/ defects. The two test panels pictured show the impact of mechanical drilling around the proximity of the holes resulting in delamination within the laminates and bulging on the back surface of the plate." MISTRAS Gp. 7/2015 Entry Exit Advanced Material Solutions (Perforating Composite Materials)

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