Manufacturing Knowledge Base
There is relatively little knowledge on how to machine cartridges available. We
Ingun Fixtures and Cartridges
All Ingun cartridges follow similar characteristics, they have G10/FR4 Probe Plate and Moving Plate, and a Polycarbonate Pressure Plate. The exact make up of the G10/FR4 varies depending on the specific cartridge type (Normal/Uncoated vs ESD).
Drill: Ingun KS-550 WL Press-Fit
To use standard PCB Drill bits, we've found a 2 step process to work best for drilling these holes. A 1mm hole is drilled through the entire plate, followed by a 1.05mm hole that is drilled to the collar depth.
| Drill Size | Bottom Height Offset |
|---|---|
| 1mm | 0mm |
| 1.05mm | 2.6mm |
Drill 1: 1mm Through-Hole
Looking at these Fusion 360 drill operation settings, here's how I would document them for a VitePress docs website:
Tool Configuration
- Tool: #1 - Ø1.0mm drill
- Operation Type: DRILL - 1MM DRL
Feed & Speed Parameters
| Parameter | Value |
|---|---|
| Spindle Speed | 15,000 RPM |
| Surface Speed | 49.4801 m/min |
| Plunge Feedrate | 700 mm/min |
| Plunge Feed per Revolution | 0.0466667 mm |
| Retract Feedrate | 700 mm/min |
| Retract Feed per Revolution | 0.0466667 mm |
| Coolant | Disabled |
| Use Feed per Revolution | No |
Cycle Parameters
| Parameter | Value |
|---|---|
| Cycle Type | Chip breaking |
| Pecking Depth | 0.2625 mm |
| Pecking Depth Reduction | 0 mm |
| Minimum Pecking Depth | 0.2625 mm |
| Accumulated Pecking Depth | 2.625 mm |
| Chip Break Distance | 0.1 mm |
| Dwelling Period | 0 s |
Height Configuration
| Height Type | Reference | Offset |
|---|---|---|
| Clearance Height | Retract height | 10 mm |
| Retract Height | Highest point of stock | 5 mm |
| Feed Height | Top height | 5 mm |
| Top Height | Highest point of stock | 0 mm |
| Bottom Height | Hole bottom | 0 mm |
Additional Settings
- Drill Tip Through Bottom: Enabled
- Break-through Depth: -0.2mm
Notes
- This configuration uses a chip breaking cycle with small pecking depths (0.2625 mm) suitable for the 1.05mm drill diameter
- The operation maintains constant pecking depth throughout (no reduction)
- Conservative feed rates are set at 700 mm/min for both plunge and retract movements
- The drill will stop 0.2mm Below the hole bottom, ensuring the drill bit breaks through the plate
Drill 2: 1mm Through-Hole
Looking at these Fusion 360 drill operation settings, here's how I would document them for a VitePress docs website:
Tool Configuration
- Tool: #2 - Ø1.05mm drill
- Operation Type: DRILL - 1.05MM DRL
Feed & Speed Parameters
| Parameter | Value |
|---|---|
| Spindle Speed | 15,000 RPM |
| Surface Speed | 49.4801 m/min |
| Plunge Feedrate | 700 mm/min |
| Plunge Feed per Revolution | 0.0466667 mm |
| Retract Feedrate | 700 mm/min |
| Retract Feed per Revolution | 0.0466667 mm |
| Coolant | Disabled |
| Use Feed per Revolution | No |
Cycle Parameters
| Parameter | Value |
|---|---|
| Cycle Type | Chip breaking |
| Pecking Depth | 0.2625 mm |
| Pecking Depth Reduction | 0 mm |
| Minimum Pecking Depth | 0.2625 mm |
| Accumulated Pecking Depth | 2.625 mm |
| Chip Break Distance | 0.1 mm |
| Dwelling Period | 0 s |
Height Configuration
| Height Type | Reference | Offset |
|---|---|---|
| Clearance Height | Retract height | 10 mm |
| Retract Height | Highest point of stock | 5 mm |
| Feed Height | Top height | 5 mm |
| Top Height | Highest point of stock | 0 mm |
| Bottom Height | Hole bottom | 2.6 mm |
Additional Settings
- Drill Tip Through Bottom: Disabled
Notes
- This configuration uses a chip breaking cycle with small pecking depths (0.2625 mm) suitable for the 1.05mm drill diameter
- The operation maintains constant pecking depth throughout (no reduction)
- Conservative feed rates are set at 700 mm/min for both plunge and retract movements
- The drill will stop 2.6 mm above the hole bottom (not drilling through)
Drill: Ingun KS-075 WL Press-Fit
For the KS-075 WL Press-Fit, a single drill operation with a 1.4mm drill bit is used to create the press-fit holes.
Drill: 1.4mm Through-Hole
Tool Configuration
- Tool: #3 - Ø1.4mm drill
- Operation Type: DRILL - 1.4MM DRL
Feed & Speed Parameters
| Parameter | Value |
|---|---|
| Spindle Speed | 15,000 RPM |
| Surface Speed | 65.973 m/min |
| Plunge Feedrate | 700 mm/min |
| Plunge Feed per Revolution | 0.0466667 mm |
| Retract Feedrate | 700 mm/min |
| Retract Feed per Revolution | 0.0466667 mm |
| Coolant | Disabled |
| Use Feed per Revolution | No |
Cycle Parameters
| Parameter | Value |
|---|---|
| Cycle Type | Chip breaking |
| Pecking Depth | 0.35 mm |
| Pecking Depth Reduction | 0 mm |
| Minimum Pecking Depth | 0.35 mm |
| Accumulated Pecking Depth | 3.5 mm |
| Chip Break Distance | 0.1 mm |
| Dwelling Period | 0 s |
Height Configuration
| Height Type | Reference | Offset |
|---|---|---|
| Clearance Height | Retract height | 10 mm |
| Retract Height | Highest point of stock | 5 mm |
| Feed Height | Top height | 5 mm |
| Top Height | Highest point of stock | 0 mm |
| Bottom Height | Hole bottom | 0 mm |
Additional Settings
- Drill Tip Through Bottom: Enabled
- Break-through Depth: -0.2mm
Notes
- This configuration uses a chip breaking cycle with pecking depths (0.35 mm) suitable for the 1.4mm drill diameter
- The operation maintains constant pecking depth throughout (no reduction)
- Conservative feed rates are set at 700 mm/min for both plunge and retract movements
- The drill will stop 0.2mm below the hole bottom, ensuring the drill bit breaks through the plate
Drill: Ingun KS-100 WL Press-Fit
For the KS-100 WL Press-Fit, a single drill operation with a 1.75mm drill bit is used to create the press-fit holes.
Drill: 1.75mm Through-Hole
Tool Configuration
- Tool: #4 - Ø1.75mm drill
- Operation Type: DRILL - 1.75MM DRL
Feed & Speed Parameters
| Parameter | Value |
|---|---|
| Spindle Speed | 15,000 RPM |
| Surface Speed | 82.466 m/min |
| Plunge Feedrate | 700 mm/min |
| Plunge Feed per Revolution | 0.0466667 mm |
| Retract Feedrate | 700 mm/min |
| Retract Feed per Revolution | 0.0466667 mm |
| Coolant | Disabled |
| Use Feed per Revolution | No |
Cycle Parameters
| Parameter | Value |
|---|---|
| Cycle Type | Chip breaking |
| Pecking Depth | 0.4375 mm |
| Pecking Depth Reduction | 0 mm |
| Minimum Pecking Depth | 0.4375 mm |
| Accumulated Pecking Depth | 4.375 mm |
| Chip Break Distance | 0.1 mm |
| Dwelling Period | 0 s |
Height Configuration
| Height Type | Reference | Offset |
|---|---|---|
| Clearance Height | Retract height | 10 mm |
| Retract Height | Highest point of stock | 5 mm |
| Feed Height | Top height | 5 mm |
| Top Height | Highest point of stock | 0 mm |
| Bottom Height | Hole bottom | 0 mm |
Additional Settings
- Drill Tip Through Bottom: Enabled
- Break-through Depth: -0.2mm
Notes
- This configuration uses a chip breaking cycle with pecking depths (0.4375 mm) suitable for the 1.75mm drill diameter
- The operation maintains constant pecking depth throughout (no reduction)
- Conservative feed rates are set at 700 mm/min for both plunge and retract movements
- The drill will stop 0.2mm below the hole bottom, ensuring the drill bit breaks through the plate
Looking at these Fusion 360 2D pocket operation settings, here's how I would document them for a VitePress docs website:
Pocket: 2mm Square Endmill
Do to our CNC limitations, we run very conservative feeds and speeds when pocketing and removing lots of material. Use these as guide lines. We design all fixtures around using a 2mm Flat Endmill for these operations, in special cases we may use larger or smaller endmills depending on feature size and amount of material that needs to be removed.
Tool Configuration
- Tool: #5 - Ø2mm flat endmill
- Operation Type: 2D POCKET - 2MM POCKET
Feed & Speed Parameters
| Parameter | Value |
|---|---|
| Spindle Speed | 15,000 RPM |
| Surface Speed | 94.2478 m/min |
| Ramp Spindle Speed | 15,000 RPM |
| Cutting Feedrate | 800 mm/min |
| Feed per Tooth | 0.0266667 mm |
| Lead-In Feedrate | 800 mm/min |
| Lead-Out Feedrate | 800 mm/min |
| Transition Feedrate | 800 mm/min |
| Ramp Feedrate | 333.333 mm/min |
| Plunge Feedrate | 266 mm/min |
| Plunge Feed per Revolution | 0.0177333 mm |
| Coolant | Disabled |
Passes Configuration
| Parameter | Value |
|---|---|
| Tolerance | 0.1 mm |
| Sideways Compensation | Left |
| Minimum Cutting Radius | 0 mm |
| Maximum Stepover | 1.2 mm |
| Smoothing Deviation | 0.1 mm |
| Preserve Order | No |
| Both Ways | No |
| Use Morphed Spiral Machining | No |
| Allow Stepover Cusps | No |
Multiple Depths Settings
| Parameter | Value |
|---|---|
| Multiple Depths | Enabled ✓ |
| Maximum Roughing Stepdown | 0.5 mm |
| Finishing Stepdowns | 0 (disabled) |
| Finishing Stepdown | 0.2 mm |
| Wall Taper Angle | 0° |
| Use Even Stepdowns | Yes ✓ |
| Order by Depth | No |
| Order by Step | No |
Linking Parameters
| Parameter | Value |
|---|---|
| High Feedrate Mode | Preserve existing |
| Allow Rapid Retract | Yes ✓ |
| Safe Distance | 1.5 mm |
| Keep Tool Down | Yes ✓ |
| Maximum Stay-Down Distance | 50 mm |
| Lift Height | 0 mm |
Leads & Transitions
| Parameter | Value |
|---|---|
| Lead-In (Entry) | Enabled ✓ |
| Horizontal Lead-In Radius | 0.2 mm |
| Lead-In Sweep Angle | 90° |
| Linear Lead-In Distance | 0.2 mm |
| Perpendicular | No |
| Vertical Lead-In Radius | 0.2 mm |
| Lead-Out (Exit) | Enabled ✓ |
| Same as Lead-In | Yes ✓ |
Ramp Settings
| Parameter | Value |
|---|---|
| Ramp Type | Helix |
| Ramping Angle | 2° |
| Maximum Ramp Stepdown | 0.5 mm |
| Ramp Clearance Height | 0.1 mm |
| Ramp Radial Clearance | 0 mm |
| Helical Ramp Diameter | 1.9 mm |
| Minimum Ramp Diameter | 1 mm |
Positions
- Predrill Positions: Selected
- Preferred Lead-In Points: Available for selection
- Exit Positions: Available for selection
Additional Options (Disabled)
- Finishing Passes: Not configured
- Stock to Leave: Not configured
- Smoothing: Not configured
- Feed Optimization: Not configured
Notes
- This configuration uses conservative depths of cut (0.5 mm maximum) suitable for the 2mm tool diameter
- Helical ramping at 2° provides smooth entry into the material
- The operation maintains tool engagement with "Keep Tool Down" enabled for efficiency
- Even stepdowns are used for consistent chip load throughout the operation
- Left compensation is applied for climb milling strategy