For decades, machining hard materials such as sapphire, quartz, alumina and zirconia has presentedFigure 1: INSACO has developed a technique that allows for precise and reliable internal threading of exceptionally hard materials. Source: INSACO significant challenges. One of the most difficult tasks has been the creation of internal threads within these materials. Traditional manufacturing processes have largely been limited to external threading or bonding solutions, leaving engineers and manufacturers constrained in their designs.

INSACO has developed a groundbreaking technique that allows for precise and reliable internal threading of these exceptionally hard materials. This advancement allows for new opportunities across industries such as aerospace and defense, medical devices, optics, semiconductors and metal replacement applications.

The challenge of internal threading in hard materials

Hard materials are widely used in industries that demand superior mechanical properties, high-temperature resistance, biocompatibility and corrosion resistance. However, due to their extreme hardness and brittleness, machining internal threads has been virtually impossible using conventional cutting or drilling techniques.

Traditional alternatives, such as adhesive bonding, press-fitting or external threading, have limitations, including weaker mechanical integrity, limited design flexibility and lower durability. INSACO’s proprietary solution overcomes these issues by enabling precision internal threading that meets stringent industry requirements.

Their newest machining process allows for high-precision internal threading of sapphire, silicon carbide, quartz, alumina and zirconia. This technology utilizes advanced material removal techniques, ensuring:

• Exceptional thread accuracy and repeatability
• Minimal micro-cracking or structural damage
• High durability and mechanical strength
• Custom thread sizes and configurations to incredibly tight tolerances

This breakthrough expands design possibilities, allowing engineers to integrate these materials into new and more efficient applications.

Applications across key industries

Aerospace and defense

The aerospace and defense industries require materials that can withstand extreme conditions, including high temperatures, radiation and mechanical stress. Internally threaded hard materials can be used in:

• High-performance sensor housings
• Optical and infrared systems for defense applications
• Lightweight, high-strength components for spacecraft and satellite systems

Medical devices

Ceramics such as zirconia and alumina are highly biocompatible, making them ideal for medical applications. The ability to internally thread these materials enables:

• Precision-engineered implants with stronger mechanical interfaces
• Durable, corrosion-resistant surgical instruments
• Custom prosthetics and dental components with enhanced structural integrity

Optics and semiconductor manufacturing

Quartz and sapphire are essential materials in optics and semiconductor production due to their exceptional thermal and optical properties. Internally threaded components offer advantages such as:

• High-precision optical mounts and holders
• Advanced laser system components
• Enhanced semiconductor wafer processing tools
• Components in cryogenic applications

Metal replacement applications

Metals are widely used for threaded applications, but they suffer from issues such as corrosion, electrical conductivity and thermal expansion. Internally threaded ceramics present a superior alternative by offering:

• Chemical and corrosion resistance for harsh environments
• Non-conductive properties for electrical insulation
• High-temperature stability for extreme operating conditions

What's next?

The ability to internally thread hard materials represents a significant leap forward in precision machining. As industries continue to demand high-performance materials, INSACO’s technology paves the way for new applications and enhanced designs.

INSACO invites engineers, designers and manufacturers to explore the potential of this innovation. INSACO is poised to facilitate the creation of custom designs. They excel in creating anything their clients design. Reach out with designs, request prototypes or learn more about how their technology can be integrated into various applications.