Machining & Polishing services for sapphire tubes

Service Detail from Insaco, Inc.

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DEFENSE AND AEROSPACE
Insaco provides sapphire machining and polishing services for sapphire tubes for infrared countermeasures (IRCM) for military and VIP aircraft.

High accuracy ceramic gyroscopic components and large ceramic composites used for guidance of various aerospace applications.

Insaco is ITAR and ISO compliant and DDTC registered.

Sapphire
Anisotropic single crystal materials exhibit some properties such as thermal expansion and hardness which vary significantly by orientation. For most applications this is unimportant, however it should be considered. Since 1947, Insaco has had experience with this material and we can provide considerable insight as to how orientation might affect your application.

Sapphire is also “birefringent” which is an optical refractive property that offsets wave transmission up to 0.8% at right angles to the optic axis. Birefringence is eliminated along the optic or C-axis of the crystal. Therefore, for certain optical applications, C-axis sapphire should be specified to avoid this effect.

Industrial sapphire is created by melting aluminum oxide (Al2O3) at 2040°C and then encouraging crystal growth with a seed and careful control of the environment. Growers have developed several unique methods for growth, with varying levels of resultant quality, size, and cost. The EFG or Stephanov methods allow the directed growth of shapes like ribbon, or even tubes, however there are many limitations to what can be done. The Czochralski, HEM, or Kiropolous methods allow the highest optical quality sapphire, but the result is a rod like “blob” of crystal called a boule, that must be entirely machined into usable shapes and sizes.

Sapphire and Ruby are actually the same material with small amounts of chromium (typically ≤ 0.05% by weight) added which affects color and optical properties, while not affecting mechanical, thermal and electrical properties significantly.

Insaco Designers Guide
select materials of interest based on what is most important to your application. Once you specify which properties are most important, the "guide" searches our database of materials and presents you with various materials listing the selected properties ranked as you specify and often includes some other materials provided as references.

Watch>>>Ceramic Manufacturing and Machining Process with Insaco, Inc.

Insaco
Insaco has been fabricating precision parts from all technical ceramics since 1947. Approximately a third of our machining involves sapphire, but our capabilities go way beyond that. Insaco engineers welcome inquiries from designers contemplating specifying technical ceramics for their applications, whether prototype or full production. We only ship parts that meet agreed-to requirements, but are often able to respond to challenges and achieve results others cannot.

Watch>>>Precision Fabrication by Design

High Precision Machining of Hard Materials
Since 1947 Insaco® has been a precision machining and polishing fabricator of parts from all technical ceramics, sapphire, glass and quartz. We machine these materials to very precise tolerances (many times measured in millionths of an inch) for dimension, flatness, wedge and roundness or cylindricity. Our customers typically have a critical application that requires extremely tight tolerances in ultra-hard materials. We also have the capability to grind and polish spherical radius parts in a variety of hard materials, both inside and outside diameters, to optical requirements.

features include:

  • Extremely high accuracy and tight tolerance machining
  • Lights-out manufacturing
  • Machine automation including large capacity envelope
  • Automated centerless grinding
  • High efficiency/low cost volume production
  • Low-volume prototype machining
  • 5-axis machining capability
  • ITAR compliant
  • High-volume robotic machining
  • Video inspection and a Class 100 Cleanroom
  • Extensive Quality Control protocols
  • Sapphire tubes and polishing

 

Insaco
Insaco has been fabricating precision parts from all technical ceramics since 1947. Approximately a third of our machining involves sapphire, but our capabilities go way beyond that. Insaco engineers welcome inquiries from designers contemplating specifying technical ceramics for their applications, whether prototype or full production. We only ship parts that meet agreed-to requirements, but are often able to respond to challenges and achieve results others cannot.

Insaco also has extensive inspection and documentation procedures so parts are always to print. With a seasoned team of engineers and machine operators we are available to discuss your application needs including alternative materials and cost drivers. please click here to send a request, or visit our Frequently Asked Questions pageClick here to find out more about our company and our people.

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