2. Semiconductor Wafer Polishing
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Client Needs: A semiconductor manufacturer required a highly specialized lapping film for the polishing of silicon wafers. The film needed to handle ultra-fine abrasive sizes to ensure smooth finishes for microelectronic components.
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XYT Customization: XYT customized the diamond/aluminium oxide/silicon carbide concentration and micron size to provide a precise, ultra-fine finish without damaging the wafer's surface. The company also adapted the film’s backing material to suit the specific wafer handling equipment used in the polishing process.
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Outcome: The customized films allowed the client to achieve optimal polishing results with minimal material waste and cost, improving overall efficiency in the manufacturing process.
3. Optical Lens Polishing
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Client Needs: A manufacturer of precision optical lenses required a lapping film that could provide a high-quality finish on glass and ceramic lenses, without causing scratches or surface damage.
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XYT Customization: XYT developed a customized diamond lapping film with a lower diamond concentration to prevent over-polishing while providing a highly controlled abrasive action. They also adjusted the backing material’s flexibility to match the polishing tools used in the process.
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Outcome: The customized solution allowed the client to achieve optically perfect finishes on their lenses with a higher level of precision and minimal risk of damage, which is critical for the optical industry.
4. Medical Device Manufacturing (Surgical Instruments)
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Client Needs: A medical device company specializing in surgical instruments required lapping films for polishing stainless steel and titanium tools to achieve the required finish for biocompatibility and functionality.
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XYT Customization: XYT created a custom diamond abrasive film that was suitable for use in cleanroom environments. The film was designed to ensure an ultra-smooth finish while preventing the introduction of contaminants. Additionally, the films were manufactured in compliance with medical industry standards for biocompatibility and precision.
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Outcome: The client achieved perfectly polished instruments with enhanced durability and performance, meeting regulatory requirements for medical device manufacturing.
5. Jewelry Polishing
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Client Needs: A jewelry manufacturer needed a lapping film to polish precious metals (e.g., gold, silver) and gemstones to a high luster without causing scratches or affecting the material’s integrity.
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XYT Customization: XYT developed a custom non-diamond abrasive film with a mild abrasive concentration that was gentle on soft metals and stones. The film was also designed with a specialized backing to ensure a smooth, even finish across intricate jewelry designs.
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Outcome: The customized lapping films helped the client achieve a high-gloss finish on delicate jewelry pieces while preserving the integrity of the metals and stones, significantly reducing surface defects.
6. Aerospace Component Polishing
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Client Needs: A supplier to the aerospace industry required specialized polishing films for precision components made from superalloys and composite materials, such as turbine blades and engine parts. The challenge was to maintain the integrity of complex geometries while achieving a smooth finish.
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XYT Customization: XYT customized the abrasive particle size and film flexibility to suit the unique properties of aerospace materials. They also tailored the diamond content to provide controlled material removal without over-polishing delicate components.
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Outcome: The customized films enabled the client to achieve high-precision finishes on critical aerospace parts, ensuring optimal performance and compliance with stringent industry standards.
7. Tool and Die Manufacturing
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Client Needs: A tool and die manufacturer needed a film that could provide consistent, high-quality finishes on hard tool steel and molds, which required fine control over abrasive action to ensure a flawless surface.
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XYT Customization: XYT worked with the client to design a diamond/aluminium oxide lapping film with precise grit sizes and a more durable backing material to withstand the stresses of polishing hard materials. They also adjusted the film’s abrasive concentration to achieve the desired finish.
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Outcome: The customized films helped the client achieve long-lasting tool finishes with enhanced surface quality, improving the durability and performance of the tools and molds.
8. Prototype Polishing for Research and Development
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Client Needs: A research institution working on material science projects needed low-volume but highly precise lapping films for polishing prototype components made from various experimental materials.
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XYT Customization: XYT tailored the micron range and abrasive formulation for each material being tested. Additionally, they created small batches of films to allow the researchers to conduct trials and fine-tune their polishing processes.
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Outcome: The institution was able to achieve consistent polishing results on their prototypes, allowing for precise data collection and improved material performance.
9. Automotive Components (Engine Parts and Bearings)
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Client Needs: An automotive supplier needed a film for polishing engine parts and bearings made from high-carbon steel and ceramic materials. The finish required was critical for part longevity and performance.
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XYT Customization: XYT customized a diamond/aluminium oxide abrasive film with a specific grit size suitable for polishing hard materials without compromising the structural integrity of the parts. The films were also tailored to handle high-speed polishing processes.
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Outcome: The client successfully achieved high-precision finishes on automotive components, resulting in improved part durability and performance in high-stress environments.
10.Custom Branded Films for Niche Toolmakers
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Client: Boutique cutting tool brand
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Need: Small-batch, branded polishing films for carbide tool finishing.
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Customization:
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Private label printing and custom disc sizing.
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Small MOQ for R&D and field testing.
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Outcome: Consistent polishing quality and enhanced brand visibility.
11.R&D Support for Material Science Labs
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Client: University research lab
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Need: Custom abrasive film for prototype material testing.
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Customization:
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Mixed abrasive films (diamond + cerium oxide).
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Special formulations for unique material composites.
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Outcome: Enabled precise polishing in early-stage research projects.
Summary of XYT’s Customization Approach:
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Customized micron sizes and abrasive concentration to meet specific surface finishing needs.
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Tailored film formats (discs, sheets, rolls) and flexible backing materials to fit unique equipment and process requirements.
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Non-diamond abrasive options and specific formulations for different materials and applications.
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Prototyping and small batch production for research, development, and pilot projects.
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Expertise in meeting the requirements of highly regulated industries like Fiber Optics, medical, aerospace, and semiconductors.
Through these examples, XYT demonstrates its capability to provide highly tailored and industry-specific solutions for a wide range of polishing, grinding, and finishing applications. Their flexibility in responding to unique client needs makes them a valuable partner for businesses seeking precision and customization.
