Cycle experiment, the Japanese enterprise finally broke the hard and brittle material problem

Abstract Based on multiple news sources, Japan's TOP Seiko (TOP SEIKO) is a highly regarded company that specializes in the precision cutting of "hard and brittle" materials. The company's primary materials include ceramics such as alumina (Al₂O₃) and silicon carbide (SiC), as well as challenging metals like pure tungsten (W) and molybdenum (Mo). These materials are often used in high-tech industries where precision and durability are critical.
TOP Seiko has built a strong reputation for its ability to handle complex machining tasks efficiently. In the ceramic sector, they produce components like wafer adsorption plates for semiconductor manufacturing equipment and shower plates for CVD (Chemical Vapor Deposition) systems. For metal parts, their work includes applications in radiation shielding, X-ray equipment, and medical imaging devices. Their expertise lies in achieving high-precision results quickly, even with materials that are notoriously difficult to machine.

One notable example is the processing of a silicon carbide (SiC) adsorption plate used in semiconductor manufacturing. This component is a disk-shaped part measuring 290 mm in diameter and 10 mm in thickness, featuring 10 concentric grooves, each 1 mm wide. Due to SiC's extreme hardness—about 1.3 times that of alumina—traditional machining methods are not effective. Instead, TOP Seiko uses ultra-fine diamond-coated drills made from super-hard alloys. However, these tools are fragile and wear out quickly. To address this challenge, the company developed an innovative method using two custom-made tools equipped with rectangular diamond segments (800 μm wide) on the bottom of a disc-shaped tool. By rotating the tool on a machining center, they can cut precise circular grooves into the workpiece efficiently.

In addition to ceramics, TOP Seiko also processes metals like tungsten and molybdenum, often using unconventional techniques. For instance, when machining molybdenum rods on an NC lathe, the company employs self-designed cutters that allow for continuous, unattended operation for up to 40–50 hours. Another unique approach involves clamping tungsten sheets without a traditional chuck, instead securing them with adhesive on a custom jig. This ensures that the entire sheet can be used without any material being lost due to clamping pressure.

According to industry reports, TOP Seiko’s success stems not only from its technical capabilities but also from its culture of problem-solving. When faced with particularly challenging machining tasks, the company relies on a collaborative, iterative process known as "looping." This method involves three key steps: first, observing the entire machining process before, during, and after; second, forming hypotheses based on those observations; and third, testing those hypotheses through trial and error. Through this cycle of experimentation and refinement, the company has developed several unconventional yet highly effective machining techniques that defy traditional expectations.
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