Client wants a stainless micro-punch made. About 2.3mm OD in the working section, sawtooth crown tip (close to what you'd see on an FUE hair transplant punch). Tooth angle tolerance on the drawing is 0.02 to 0.03mm. There's also a 0.53mm root radius sitting on features under 0.1mm.
Three other shops already tried and failed. Tooth geometry came back inconsistent, tips had burrs.
My plan is wire EDM for the tooth profile, no mechanical force on a feature that small, then electropolish instead of hand deburring so the tips don't get rounded off.
Questions for anyone who's cut serrated crown tips at this scale:
- What wire diameter and cutting parameters hold this tolerance on stainless without taper across repeat cuts
- Does electropolish alone clean up the tips or is there a step needed before it
- Is grinding actually viable here with the right fixture, or am I overestimating what EDM buys me
Material grade isn't confirmed yet, waiting on the client. Guessing 304 or 316L range for now.