Integrated CAD/CAM Approach for Parametric Design and High-Precision Microfabrication of Planar Functional Structures Comprising Radially Oriented V-Grooves

Abstract

High-precision microfabrication is essential for enhancing or enabling new functionalities in parts and tooling surfaces. V-groove structures are commonly used in surface engineering for diverse applications. Selecting the optimal V-groove shape, array, and fabrication method is crucial for achieving the desired performance. This study integrates the parametric definition of V-groove structures in both design and fabrication modules using three main function blocks (MFBs). MFB1 defines a single V-groove’s parametric model using specific input parameters. MFB2 transforms these parameters into equations to generate a CAD model of the surface. MFB3 combines inputs from MFB1 with parameters related to cutting tool geometry, cutting strategy, and process planning, producing functional NC code for the machine tool. The approach focuses on micromachining radial V-grooves on planar surfaces, requiring precise alignment and multi-axis single-point diamond cutting (SPDC) with rotation tool center point (RTCP) support. Testing on acrylic samples achieved ±0.1° orientation accuracy and ±2 μm positional accuracy, demonstrating potential for applications in drag reduction, fouling resistance, light guiding, and open microfluidics.