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Milling Bits / Mühlbauer DICL 5000

Hold ±2 microns
at 5,000 UPH.
Every card, every shift.

AA Enterprises engineers dual-interface and ID-1 milling bits purpose-built for the Mühlbauer DICL 5000 — matched to its throughput and cavity geometry, not just its shank size.

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±2μm
Position Tolerance
5,000
UPH Line-Matched
1.2M+
Cycle Tool Life
USA
Stocked & Shipped
AA Enterprises precision milling bit positioned above a dual-interface smart card module, chip contacts visible, machine instrumentation in the background.
2-FLUTE GROUND GEOMETRY
SHANK RUNOUT <2μm
POCKET DEPTH 0.50mm ±3μm
FIG. 01 — CAVITY MILLING, DUAL-INTERFACE MODULE REF. DICL-5000-CT
Independent tooling supplier — not affiliated with Mühlbauer Carbide substrate, sub-micron grain TiAlN / DLC hybrid coating Lot-traceable, USA warehoused

Spec Sheet — 01

Engineered for the cut, not the catalog

Dual-interface cavity milling and standard ID-1 pocketing put different loads on a bit — laminate versus PVC/PC, antenna clearance versus flat-pocket finish. Every AA Enterprises bit is ground to the load it's actually cutting.

Substrate

Sub-micron grain carbide core

Fine-grain tungsten carbide substrate holds a sharper edge through extended runs, resisting the micro-chipping that shows up as pocket-wall roughness at high UPH.

GRAIN SIZE <0.5μm
Coating

TiAlN / DLC hybrid coating

Dissipates heat generated by sustained 5,000 UPH cycle rates and resists epoxy/adhesive buildup on the flute face during continuous inline operation.

RATED TO 900°C SURFACE TEMP
Geometry

Flute pitch tuned for card substrates

2-flute and 4-flute profiles clear PVC, PC, and epoxy swarf cleanly at rated spindle RPM — no re-cutting debris, no re-deposit on the pocket wall.

2-FL / 4-FL AVAILABLE
Runout

Ground shank concentricity

Held under 2 microns across the full magazine load, so cavity depth doesn't drift bit-to-bit or shift-to-shift on the DICL 5000's tool changer.

RUNOUT <2μm @ RATED RPM
Clearance

Antenna & tape-layer safe profile

Cutting depth and diameter are calibrated to clear embedded antenna windings and adhesive tape layers during dual-interface cavity milling, without nicking either.

CAVITY DEPTH 0.30–0.60mm
Duty Cycle

Rated for continuous inline runs

Coating and edge geometry are selected for 24/7 duty — not benchtop sampling — so tool life holds across full production shifts, not just a qualification lot.

1.2M+ CYCLES / BIT
APPLICATION — DUAL-INTERFACE

Cavity Cutting

High-speed cavity milling for embedded module + antenna cards demands a bit that clears TeConnect®-type adhesive tape and PVC/PC laminate without drag, while holding depth tight enough for consistent module bonding. Our helix angle and coating are set specifically for that combination — not adapted from a general PCB or ID-1 bit.

APPLICATION — ID-1 STANDARD

Card Pocketing

Standard ID-1 pocket milling (ISO/IEC 7810 format) calls for a clean flat-bottom cut and repeatable pocket geometry at volume. Our ID-1 profile is ground to spec pocket geometry directly off the machine — no secondary finishing pass required before module placement.

Compatibility Map

Built against the DICL 5000's own numbers

We spec every bit against what the Mühlbauer DICL 5000 Dual-Interface Smart Card Production System actually demands at line speed — not a generic milling-bit datasheet.

DICL 5000 Requirement AA Enterprises Bit Spec Result on the Line
TeConnect® adhesive tape milling, dual-interface lamination Low-drag flute coating + tuned helix angle Clean tape-layer separation — no adhesive drag, no module lift during cavity cutting
Chip pocket milling accuracy for module seating ±2μm depth control, ground shank concentricity Consistent module seating depth across the full production run
Continuous inline production at 5,000 UPH 1.2M+ rated cycle life per bit Fewer changeovers — line speed holds shift over shift
Standard ID-1 card pocketing (ISO/IEC 7810) Dedicated ID-1 geometry profile Full-spec pocket geometry straight off the machine, no rework
High-frequency spindle operation Dynamic runout <2μm at rated RPM Reduced vibration, longer spindle bearing life
Multi-shift, 24/7 duty cycle TiAlN/DLC hybrid coating, rated to 900°C No edge degradation across continuous production cycles

Mühlbauer, DICL 5000, and TeConnect are registered trademarks of Mühlbauer Group. AA ENTERPRISES is an independent manufacturer of compatible high-precision tooling components and has no affiliation, sponsorship, or official endorsement with the original equipment manufacturer.

Request a Quote

Talk to engineering, not a queue.

Tell us your machine, application, and volume. We'll come back with bit specs, lead time, and pricing — with sample bits available for qualification runs.

  • Response within 1 business day
  • Sample bits available for line qualification
  • NDA available on request
  • USA-based stock and shipping
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