Ceramic machining Machining the hardest ceramics with micrometer precision

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Since 2023, the precision machinist Louwers Hanique has taken the high-precision machining of brittle materials to a new level. The key factor is the use of Kern's developed ductile cutting mode in combination with the high-end machining center Kern Micro HD.

In 2012, the owners of the companies "Louwers Glastechniek" and "Pulles & Hanique" decided to combine their expertise and joined forces as Louwers Hanique BV. As specialists in the processing of technical glass, quartz, and technical ceramics, the newly founded company started with 70 employees. The successful company now employs around 185 specialists and produces high-quality components for customers from various industries.

Louwers Hanique has been growing continuously since its founding. The lead production engineer Jan van Dingenen is also very optimistic about the future: "We work very closely with innovative companies operating in high-tech markets such as semiconductor technology, medical technology, or analytics. Our extensive knowledge in processing particularly demanding materials is especially in demand."

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The main focus of the Dutch production specialists is on the manufacture of mechatronic high-end assemblies such as end effectors, mirror blocks, insulators, sensors, and ceramic housings. "We are proud to produce such high-quality components that are often very important for use in high-tech systems. This makes us a valuable partner for our customers," adds van Dingenen.

Ceramic has unique advantages as a material

Louwers Hanique offers support to its customers from an early concept and development phase through to series production. In addition to extensive expertise, a wide range of technical equipment is crucial, combining highly automated and modern CNC machining technology with advanced testing, measurement, and cleaning technologies. Only in this way is it possible to ensure 100% consistent quality while producing innovative products such as hermetically sealed feedthroughs, 3D-printed glass components, or micro-machined components made of silicon carbide.

A specialty of Louwers Hanique is the processing of ceramics. "Our customers' systems are often used in demanding environments," says van Dingenen. There, the components and assemblies used can be exposed to severe abrasive forces as well as liquids, gases, or vacuum, sometimes in combination with high temperatures. "Here, ceramics have unique advantages over metals or plastics. Silicon carbide, for example, withstands temperatures of over 1200 degrees Celsius (2192 degrees Fahrenheit) without losing its chemical structure," explains the production engineer. Furthermore, ceramic materials outgas minimally, are highly rigid, and have a low coefficient of thermal expansion.

Extremely demanding machining

As traditional processing methods for ceramics, Louwers Hanique previously primarily relied on grinding and lapping. With ductile cutting, even the hardest ceramics can now be machined by milling. This means that special PCD milling tools with geometrically defined cutting edges allow the extremely brittle material to be removed with a flowing chip. "This enables us to achieve superior surface quality with minimal roughness, so that little or no reworking by polishing is required even in critical areas. This allows us to work productively and satisfy even the most demanding customers."

In addition to the ductile cutting mode developed by Kern, an extremely process-stable machine that achieves the required highest accuracies is important for the high-precision machining of Louwers Hanique's ceramic components. High rigidity and smooth running, a fast-spinning spindle, and resistance to ceramic dust are essential prerequisites. These are particularly the attributes of the Kern Micro HD. Its clever axis arrangement protects the mechanics from abrasive dust, and the micro-gap hydrostatics ensure maximum rigidity.

The 15-kilowatt high-speed spindle of the high-end 5-axis milling center reaches speeds of up to 42,000 revolutions per minute, which allows coordinate grinding to be performed with this machine. If needed, grinding can first be done with grinding pins, and then ductile milling can be performed with PCD milling tools without changing setups.

For lead production engineer Jan van Dingenen, the decision to invest in Kern was absolutely the right one. He emphasizes not only the outstanding technology but also the excellent collaboration with all the people involved, especially with Encoma owner John Snijders: "He supported us throughout the entire purchasing process and was even present at the commissioning of the Kern Micro HD. Everything worked out wonderfully, and we are happy to now be part of the Kern family."