An investigation and analysis of 'headers' in a high-fidelity pin-tool matrix

Pin tools generate three-dimensional profiles by the juxtaposition of pins in a matrix. To provide a higher surface definition, high-fidelity pin tools use small pins (sub-2 mm) in a close-packed arrangement; a consequence is the requirement for lateral clamping of the matrix to maintain the integrity of pin positions under applied process loads. This research investigates clamping of high-resolution pins; presents a heuristic rule on tool resolution; and shows that a method to determine the worst-case header depression force is theoretically in error. A novel square-with-rounded-corners (SRC) pin section is used that offers tool performance advantages by amending an observed matrix-build limitation from an absolute dimension to a variation in header section dimension. Results from experiments on matrix clamp-force transmission indicate that matrix disturbance and 'lateral adjustment' generate performance variations.