Official Achievement Announcement

Drawing on profound expertise in multi‑axis precision machining and micro‑specialized machining, we have successfully overcome manufacturing challenges for high‑density, irregular multi‑lumen distal housings and launched the MixCore Series. Without increasing outer diameter, this series enables complex combinations of asymmetric lumens including D‑shaped, rectangular and trapezoidal profiles within the housing, and stably processes ultra‑thin partition ribs with a thickness of only 0.05 mm separating adjacent lumens. This breakthrough allows next‑generation endoscopes to integrate larger‑size image sensors, more functional channels (e.g., dedicated water‑supply/air‑supply/suction/instrument channels) and auxiliary sensors, leading the design trend of modularized functions and high‑density integration at endoscope distal tips.

R&D Background & Pain Points

Rapid advances in endoscopic diagnosis and treatment have triggered explosive growth in functional demands for distal tips: from simple observation to simultaneous irrigation, suction, biopsy, therapeutic interventions (e.g., laser, radiofrequency), and multi‑dimensional sensing (e.g., pressure, ultrasound). However, outer diameters of endoscopes are constrained by natural human body lumens and cannot be infinitely enlarged. Engineers are thus forced to arrange various channels within a limited cross‑sectional area (e.g., the distal tip of a 2.8‑mm‑diameter gastrointestinal endoscope), much like planning a miniature urban layout. Conventional circular drilling is inefficient with low space utilization and cannot form irregular lumens to accommodate non‑cylindrical components. Moreover, machining ultra‑thin partition ribs for separated lumens easily causes rib bending, fracture or dimensional out‑of‑tolerance due to insufficient tool rigidity, cutting forces or thermal deformation - a universally recognized no‑go zone in manufacturing.

Core Technological Innovations

1. Topology‑Optimization‑Based Lumen Layout & Rib DesignWe engage and provide engineering optimization services from clients' conceptual design stage. Using topology‑optimization algorithms, we automatically generate an optimally distributed rib network under constraints of given outer contours and component spatial requirements. Targeting maximum overall stiffness and minimum stress concentration, the algorithm produces bionic rib geometries (e.g., curved ribs, honeycomb ribs) rather than simple straight partitions. This design enables even 0.05‑mm‑thick ribs to achieve remarkable bending and compressive resistance, laying a feasible design foundation for subsequent machining.
2. Layered Scanning Micro‑Electrical Discharge Machining (μ‑EDM)For ultra‑thin ribs, deep narrow grooves and irregular profiles, we mainly adopt micro‑electrical discharge machining. We have developed layered‑scanning discharge machining using micro‑electrodes with diameters of 0.02–0.1 mm. By precisely controlling single‑pulse energy and discharge gaps, micron‑scale material ablation is achieved with nearly zero machining force, avoiding extrusion‑induced deformation of thin ribs from mechanical cutting. Combined with a multi‑electrode coordination strategy and on‑line electrode wear compensation, lumen structures with arbitrary complex 2D cross‑sections and depths of several millimeters are machined with an accuracy of ±3 μm.
3. Ultra‑High‑Speed Micromilling with On‑Line Vibration SuppressionFor mill‑able regions, we use ultra‑high‑speed motor spindles with a rotational speed up to 160 000 RPM paired with dynamically balanced micro‑end‑mills (minimum diameter: 0.1 mm). Machine tools integrate an active vibration control system that counteracts chatter generated during cutting in real time via piezoelectric actuators. Meanwhile, advanced strategies such as peck milling and helical interpolation, together with minimum quantity lubrication (MQL), minimize cutting forces and optimize heat dissipation during ultra‑thin rib machining, maintaining dimensional stability and perpendicularity of ribs.

Working Mechanism

The core value of MixCore Series housings lies in redefining the spatial constitution of endoscope distal tips. Essentially, their complex multi‑lumen structures act as precisely calculated micro‑fluid and pipeline distributors. D‑shaped or rectangular lumens closely wrap CMOS image sensors, freeing precious rounded‑corner space for arranging illumination fibre bundles. Optimized fluid cross‑sections of dedicated irrigation and suction channels reduce clogging risks and improve efficiency. Channels reserved for miniature ultrasound probes or laser fibres feature precision guiding and sealing structures at inlets. Separating these functional units are 0.05‑mm‑thick ribs - thin yet strong, like load‑bearing walls in high‑rise buildings. Fabricated from high‑strength stainless steel or titanium alloy and optimized via bionic topology design, they enable uniform stress transfer across the rib network and prevent fracture caused by local stress concentration. The entire housing thus becomes a miniature functional carrier balancing ultra‑high space utilization and structural integrity.

Performance Validation

We conducted extreme tests on MixCore Series housings: in pressure testing, internal independent fluid channels remained leak‑free under 0.5 MPa pressure with no cross‑talk between adjacent lumens. Micro‑probe loading tests on 0.05‑mm ribs revealed they withstand lateral forces exceeding 5 N without plastic deformation or fracture, far exceeding actual in‑service loads. When assembled into endoscopes, functional channels integrated inside (optical fibres, wires, instruments) showed no damage or performance degradation caused by housing deformation after tens of thousands of fatigue bending cycles simulating intestinal peristalsis.Client application cases show that one manufacturer used this technology to integrate a high‑definition camera, two illumination fibre channels, one laser channel, one irrigation channel and a 1.2‑mm working instrument channel into a 3.5‑mm‑diameter ureteroscope distal tip, achieving unprecedented functional integration. This product has obtained FDA approval and been successfully launched on the market.

R&D Strategy & Philosophy

We pursue the strategy of function‑oriented integrated design‑and‑manufacturing. For ultra‑complex components such as distal housings, design and manufacturing must be deeply integrated from the very beginning. Our engineers serve as both designers and process specialists. What we provide clients is not merely machining services, but complete solutions from functional checklists to manufacturable designs. We have built an extensive "feature‑process‑capability" database, enabling rapid matching of any new design concept with validated manufacturing processes or triggering new process development.Our philosophy is: No geometric shape is unmanufacturable; only manufacturing methods remain undiscovered. We view every high‑difficulty order as an opportunity for technological advancement, committed to pushing the limits of precision manufacturing and removing barriers for miniaturization and integration of medical devices.

Future Outlook

Future integration at endoscope distal tips will evolve toward micro‑system assembly and heterogeneous fusion. We are exploring hybrid molding combining micro‑molding with metal housings to develop secondary molding technologies for precision plastic liners or functional components, creating hybrid‑material distal structures. Meanwhile, we study direct formation of embedded functional features such as micro‑fluid valves and optical filter mounting slots inside housings during machining.Looking further ahead, we focus on integrating micro‑electro‑mechanical systems (MEMS) with housings. In the future, partial optical or sensor functions may be directly fabricated on silicon or glass substrates of housings, ultimately achieving the ultimate miniaturization goal of chip‑as‑distal‑tip, opening new horizons for non‑invasive or ultra‑minimally invasive diagnosis and treatment.