Context & Need

The smart card industry requires precise milling solutions for prototype development, small production runs, and laboratory testing. Standard industrial milling machines are often designed for high-volume production, making them less suitable for customized or small-batch requirements.

To address this, manufacturers need a versatile, high-precision, and easy-to-use desktop milling machine that supports a variety of materials and configurations while maintaining high accuracy.

Developed Solution

The BGi051U is a manual insertion card milling machine designed specifically for small-scale smart card production and biometric sensor milling. Below are the key technical aspects that make it an ideal solution.

  • Touchscreen Interface: Supports up to 30 memorized programs, enabling quick adjustments for different milling requirements.
    Standalone Operation: Does not require complex integration into a production line, making it ideal for R&D environments, prototyping, and small production batches.

    🔹 How it meets the need:
    For small-scale production, flexibility and ease of use are essential. The BGi051U allows operators to quickly switch between different card milling programs without requiring extensive setup.

  • Milling Accuracy: X, Y: 0.025mm, Z: 0.015mm ensures high precision for smart card manufacturing.
    Compatible with Various Materials: Supports PVC, PET, ABS, PC, making it suitable for dual-interface card prototyping.
    Biometric Sensor Milling: Optimized for precise milling of biometric card sensors, expanding its applications beyond standard chip embedding.

    🔹 How it meets the need:
    Smart card manufacturers and R&D teams need a precise and adaptable milling solution to test new materials and designs. The BGi051U's high accuracy ensures flawless chip and sensor integration.

  • Processing Speed: Capable of up to 1000 units per hour depending on the configuration.
    Supports Various Card Dimensions: Compatible with ID3 and custom sizes, allowing flexibility in production.

    🔹 How it meets the need:
    R&D and prototyping require fast iterations while maintaining quality. The BGi051U balances speed and precision, making it ideal for efficient small-scale production.

  • Full Card Milling Option: Enables complete card milling instead of localized processing.
    Double Head Option: Increases efficiency by milling multiple sections simultaneously.
    Manual Chip Implanting Option: Allows controlled chip placement for prototyping and testing.

    🔹 How it meets the need:
    The modular options make the BGi051U adaptable to different use cases, ensuring manufacturers and researchers can configure the machine according to their specific project needs.

  • Dimensions: 580mm (W) x 460mm (D) x 640mm (H) – Compact enough for desktop or small lab environments.
    Weight: 51 kg, making it portable and easy to integrate into different workspaces.
    Power Requirements: 100-240V AC, 50-60Hz single phase, 700W max consumption.
    Pneumatic Pressure: 6 bars, ensuring consistent milling force.

    🔹 How it meets the need:
    Many high-precision milling machines are large and complex, requiring dedicated industrial setups. The BGi051U's compact form factor makes it ideal for R&D, university labs, and low-volume smart card production facilities.

The projects and images presented on this site illustrate projects I contributed to during my previous professional experiences or projects completed with zaKraft. They aim to showcase my skills in design and project management. These machines are not offered for sale by zaKraft.

Results & Impact

High precision milling – Ensures accuracy within 0.025mm, ideal for sensitive applications like biometric cards.
Versatile material compatibility – Works with PVC, PET, ABS, PC, suitable for various smart card types.
Fast turnaroundUp to 1000 units per hour, optimizing production efficiency.
Compact and user-friendlyDesktop size with an intuitive interface, making it easy to use.
Flexible configuration – Optional full card milling, dual head, and manual chip implanting for customized needs.

Previous
Previous

Easy-LIT – Electric Litter Scarifier for Poultry Farming

Next
Next

BGi051H – Manual Chip Implanting Machine for Smart Card Industry