Overcoming the Challenge of a Custom Cage
A localization project for high-precision rotary table bearings used in wafer thinning and polishing machines.
Project Overview
Securing a critical bearing for wafer flatness
Our customer is a semiconductor manufacturer in China. Wafer thinning and polishing are among its core processes, where equipment accuracy and stability directly influence the surface flatness of finished wafers.
The machines had long used imported precision double-direction axial angular contact ball bearings for rotary tables. High purchase costs, uncertain lead times and supply interruption risk created an urgent need for a reliable localized solution.
Figure 1
The initial substitute was easier to manufacture but did not pass performance validation.
The Core Challenge
A large non-standard cage stopped development
Technical analysis of the original drawings revealed a large custom nylon cage. At the time, no supplier in our existing network could manufacture it to the required size and stability, temporarily suspending the project.
To move quickly, our engineers redesigned the bearing around a brass cage. The first samples, however, did not meet expectations for practical performance and overall reliability. The easier material choice was not the right engineering answer.
Large cage dimensions demanded dedicated moulding capability
Accuracy, rigidity and consistency could not be compromised
The initial brass-cage solution failed validation
Engineering Development
From an unsuccessful prototype to a dedicated development program
We reassessed the structure, material and manufacturing process, then funded a joint program with a specialist cage manufacturer.
Structure Review
Re-evaluated the bearing architecture and the cage's influence on operating stability.
Dedicated Tooling
Developed specialized moulds and matched them to larger injection-moulding equipment.
Material Validation
Tested nylon material and forming parameters for dimensional and operating consistency.
Process Optimization
Refined machining, assembly and precision-control procedures around the new cage.
Custom Solution
The special nylon cage became the decisive breakthrough
After repeated structural optimization, mould adjustment, material validation and process trials, the joint development team produced a custom nylon cage that met the bearing's application requirements.
With the key component resolved, LZK optimized the complete machining and assembly route and manufactured a bearing series with high accuracy, stable quality and reliable operating performance.
- Custom nylon cage
- Specialized mould development
- Stable forming process
- Precision-controlled assembly
Manufacturing & Verification
A manufacturable solution, verified in detail
The customized component was integrated into a controlled production route covering machining, assembly and final inspection.
Project Results
Lower procurement cost and a more secure supply chain
Installed bearings met the machine's accuracy and operating-stability requirements while costing significantly less than the imported products. Local production also reduced uncertainty in lead time and continuity of supply.
The project developed into a long-term partnership. The customer now also turns to LZK for bearing selection, failure analysis and application support across other models.
Localization generates a substantial cost benefit at the complete-machine level.
We do more than supply bearings. We turn structural analysis, material optimization, process development and supply-chain collaboration into practical replacement solutions.
Integrated Capability
Solving non-standard challenges across the project
Reverse Analysis
Understanding the original bearing, interfaces and critical performance requirements.
Component Development
Creating a large custom cage where no ready-made supply solution existed.
Process Engineering
Aligning moulding, machining, assembly and precision control.
Application Support
Continuing selection, failure-analysis and maintenance support after delivery.
Engineering Consultation
Facing a difficult non-standard bearing component?
Share the drawings, operating conditions and supply challenge. Our engineers can assess a practical localization route.