Abstract

This thesis presents an investigation on the gravity feed micro-drilling spark assisted chemical engraving (GFMD-SACE). The competitive advantage of the GFMD-SACE process is its combined simplicity and low-cost with high aspect ratio and smooth surface finish. As long as these values are well-preserved and intensified, this process will take a share in the market of micro-fabrication. The main objective of this study is to establish a systematic approach of the improvement in GFMD-SACE by minimizing initially different variabilities in the process. The methodology is to observe in details the process by adapting the six sigma procedures to determine the major error states and their root causes. To this end, the process initial documentations are created such that it keeps the door wide open for continuous improvement. Based on the initial evaluation, an improved process is recommended on the tool electrode thermal and material properties, electrolyte levels and the use of pulse voltage. Compared to the traditional process, the improvement procedure shows less variability and more capability to achieve high quality in micro-drilling