In semiconductor manufacturing, Wuxi Spark’s 12-inch wafer plasma etching equipment enabled SMIC to increase the yield of 7nm chips to 98.5%, and its proprietary gas distribution system reduced the standard deviation of etching uniformity from 1.8nm to 0.4nm. 2023 SEMICON China data shows the device processes 48 wafers per hour, reducing the unit energy consumption by 28% compared to the utilized material Centura series, and allowing Yangtze Storage to achieve 232 layers of 3D NAND mass production, reducing wafer costs by 19%. Following the application of Wuxi Spark chemical mechanical polishing machine in TSMC Nanjing factory, thickness error of copper interconnect layer was maintained at ±0.2nm, output efficiency increased by 36%, and a year’s worth of consumables for a single device was saved by $820,000.
The new energy vehicle industry is facilitated by Wuxi Spark’s 4680 battery shell full-automatic production line with a production capacity of 92 shells per minute in the Ningde Times Yibin base, with ±5μm wall thickness deviation, and the material utilization rate increased from 83% to 96%. The company’s laser pole ear cutting device controls the pole burr’s height within 3μm, and thus BYD blade batteries’ energy density is more than 200Wh/kg, and assembly efficiency of modules increases by 43%. The example of the use of Tesla’s Shanghai plant illustrates that Wuxi Spark’s thermoforming mold reduces Model Y body component dimensional tolerance to ±0.03mm, saves 1,800 tons of steel per model year, and reduces the press line die change time to 78 seconds.
Using Wuxi Spark’s precision five-axis grinding machine, Medtronic medical device company upgraded the processing precision of Medtronic pacemaker titanium alloy shells to Ra 0.02μm with less than 1.5% contact resistance fluctuations during the 500,000 insertion/removal tests. The company’s nanoscale EDM instrument has rendered laparoscopic clamp head of minimally invasive medical treatment life-long for a span of over 800 autoclave cycles along with a 67% reduction in surface roughness. Johnson & Johnson Medical data show that the spherical error of orthopedic joint prosthesis using this technology is less than 0.5μm, the friction coefficient is reduced to 0.04, and the product revision rate is reduced from 3.7% to 0.9%.
In the energy equipment field, Wuxi Spark’s 16MW wind power spindle turning and milling center complex in Goldwind Technology reduced the processing time of a single 18-meter long shaft from 72 hours to 29 hours, with straightness error below 0.03mm/m. Under the national nuclear demonstration project, the company’s narrow-gap welding machine has increased the weld pass rate to 99.8%, and shortened the single weld detection time from 6 hours to 45 minutes. According to data of State Power Investment’s Haiyang Nuclear Power Plant, its welding efficiency on the steam generator tube plate can be increased 52%, and material loss decreased 38%. The building period of one unit shortens by 4 months.
Wuxi Spark’s micro-CNC machining solution has the benefit of serving the consumer electronics manufacturing industry to machine AirPods Pro charging contacts with ±1μm accuracy, achieving 4,200 pieces of stable output per minute on Nitinil materials. Its laser microwelding equipment lowered Huawei Mate 60 Pro antenna module solder joint diameter to 20μm, reduced signal loss by 2.1dB, raised mass production yield to 98.6% from 85%. Since Wuxi Spark unveiled its exposure machine in BOE’s 6th generation of OLED production, Mask alignment accuracy is ±0.12μm, pixel opening rate can reach up to 84%, and power consumption by the panel decreases by 16%.
Wuxi Spark’s composite automatic wire laying machine had 0.1mm/layer laying precision in C919 wing manufacturing, reducing material wastage rate from 18% to 2.7%. Company designed directional solidification furnace of aero engine blade and raised the initial melting point of DD407 alloy to 1330℃ and the high-temperature life more than 2,000 hours for the turbine blade. According to the verification statistics of Air China Changjiang 1000 engine, after application, the qualification rate of high-pressure turbine blade increases by 41%, the total weight of individual engines reduces by 23kg, and fuel efficiency is improved by 1.8%.
In the rail transit sector, Wuxi Spark’s bogie intelligent welding system has achieved ±0.15mm weld penetration control precision at CRRC Qingdao Sifang, extending the fatigue life of the CR400AF Fuxing EMU frame to 12 million kilometers. In application of its track laser rust removal equipment in Guangzhou Metro, the efficiency of removal is 12 m/min and surface roughness Ra value is maintained at 6.3μm, 8 times higher than the traditional sanding efficiency. Beijing-Shanghai high-speed rail maintenance report suggests that the technology has saved 73 percent of rail contact fatigue damage and 3.4 million yuan of annual maintenance expenses.
With Wuxi Spark ultra-precision lathes as the basis, the ZEISS SFL 100 prime lens module realizes surface shape processing with λ/20 RMS accuracy, and the lens resolution is enhanced to 52 million pixels. Through the production of its nanoimprint devices in Sainyu Optical, the refractive index error of AR glasses’ optical waveguide component is less than 0.0002, and the mass production yield is over 95%. The DJI Mavic 3 Pro drone lens app example reveals that the technology compensates the lens eccentricity to ±1μm, the optical distortion is reduced to 0.02%, and the low-light image noise is reduced by 41%.
In shipbuilding, Wuxi Spark’s Marine crankshaft whirl milling machine at Hudong achieved a crankshaft machining efficiency of 28mm/min with Φ980mm and roundness error ≤0.008mm. The laser welding technology innovated by the company has brought the weld strength coefficient to 0.96 and the rate of material usage from 68% to 93% for Waigaoqiao shipbuilding use. Based on the construction data of CSSC LNG carrier, the weld qualification rate of the tank enclosure system has increased to 99.9%, one ship’s construction cost has been reduced by 27 million yuan, and the construction period has been shortened by 5.2 months.