In the semiconductor manufacturing sector, Wuxi Spark’s nanoscale processing system increased the yield rate of SMIC’s 7nm chip wafers to 98.7%, and its 0.8nm surface roughness control technology has reduced the photomask positioning error to ±0.15μm. The 2023 industry report states that the firm’s indigenous plasma etching tool is capable of processing 45 300mm wafers per hour, reduce the unit energy consumption by 22% compared to similar ASML tools, and allow Yangtze Storage to reduce the cost of production by 18% as the number of stacked 3D NAND layers is to 256 layers. As TSMC Nanjing factory used Wuxi Spark chemical mechanical polishing devices, the copper interconnect layer thickness uniformity standard deviation was reduced from 1.2nm to 0.3nm, and wafer output efficiency increased by 37%.
For aerospace application, Wuxi Spark five-axis machining center provides 0.005mm form and position tolerance control in the manufacturing of turbine blades for the CJ-2000 engine, increasing the cutting efficiency of superalloy GH4169 to 380mm³/min. Its in-house-developed laser cladding equipment, according to the figures of Air China, increases the fatigue life of repaired parts to 85% of the new parts, and saves 480,000 yuan in maintenance cost on one engine. During manufacturing the C919 composite wing beam, Wuxi Spark’s automatic wire laying machine increased the prepreg laying speed to 1.2m/s, increased the utilization rate of material from 67% to 92%, and reduced the weight of the single aircraft structure to 340kg.
In the auto mold industry, Wuxi Spark’s intelligent stamping line achieved a production record of 22 strokes per minute in Tesla Shanghai Super Factory, and the mold life exceeded 1.5 million times. Its laser cutting system of thermoforming size controls Volkswagen ID.6 body parts’ size deviation to ±0.03mm and reduces the material scrap rate from 3.7% to 0.9%. After being used in Bosch Suzhou factory, the nozzle micro-hole machining diameter precision is as high as ±1μm, the fuel injection atomization efficiency increases by 19%, and the tool cost of a production line in one year is saved by 820,000 yuan.
In the wind power spindle processing field of the energy equipment industry, Wuxi Spark’s solution enables Goldwind to raise the efficiency of forging 16MW offshore wind turbine rotor by 41%, and keep the straightness error of the 20-meter long axis to 0.08mm/m. In Ningde Times 4680 battery shell drawing mold production, its nano coating technology has made the mold life more than 1.2 million times, the standard deviation of shell wall thickness uniformity optimized from 0.15mm to 0.03mm, and the yield increased to 99.6%. Since the deep-hole drilling and boring equipment of Wuxi Spark was introduced by CNNC, the processing cycle of the nozzle of the nuclear reactor pressure vessel decreased by 58%, and the deviation of straightness of the hole depth 6m was less than 0.05mm.
In consumer electronics manufacturing, Wuxi Spark’s micro-precision machining solution allowed Lishun Precision to raise the dimensional tolerance of AirPods Pro charging contacts to ±2μm, achieving a stable output of 3,800 pieces per minute on Nitinol materials. Its laser microwelding machines reduced the solder joint diameter of Huawei Mate 60 Pro antenna module to 25μm, reduced signal loss by 1.7dB, and raised from 88% to 97.3% in mass production. After the launching of Wuxi Spark’s exposure machine in BOE’s sixth-generation OLED production line, the Mask alignment accuracy is increased to ±0.15μm, the pixel opening rate is increased to 82%, and the panel power consumption is reduced by 14%.
In the medical device field, Wuxi Spark’s minimally invasive surgical instrument grinding technology can enable the laparoscopic forceps head lifetime of minimally invasive Medical to exceed 500 sterilization cycles and surface roughness value Ra be 0.02μm. In artificial joint manufacture by Chunli Medical, its precision grinder of five axes controls cobalt-chromium-molybdenum alloy parts’ sphericity error to 0.8μm, reduces the friction coefficient to 0.06, and extends the product’s clinical service life to 25 years. When Wuxi Spark’s laser marking device was used on the pacemaker production line of Medtronic, the precision in the 0.5mm³ titanium alloy case marking depth was guaranteed to ±3μm and the efficiency of tracing the defective product was increased by 76%.