In the manufacture of semiconductors, Wuxi Spark’s 12-inch wafer etcher ensures flexible capacity expansion with a module-based structure for a single device to meet a 5-3nm process need, increase wafer processing speed from 32 to 58 wafers per hour, and reduce each unit’s power consumption by 41%. The intelligent scheduling system of the company realized the coordination of 32 equipment groups at SMIC Ningbo base, the average wafer waiting time decreased from 78 minutes to 9 minutes, and the highest equipment utilization rate reached up to 98.7%. According to SEMICON China figures in 2023, the solution reduced the price of mass production of 7nm chips by 28% and increased the output of the fab per unit area by 63%.
In new energy vehicles, Wuxi Spark’s production line of 4680 battery cases realizes 15-second high-speed transformation by adopting a flexible manufacturing system, and the material usage rate is increased from 83% to 97% as the single line’s daily capacity in Ningde Era Yibin base can be more than 320,000 pieces. Its AI visual recognition system raised the detection rate of defects to 99.992% and misjudgment to 0.008%, which allowed BYD to improve the assembly efficiency of blade battery modules by 47%. The Tesla Shanghai factory application case illustrates that the solution supports the mixed line production of 1,800 cells per hour, the equipment reuse rate is enhanced to 92%, and the production line transformation cost is reduced by 64%.
For manufacturing medical devices, Wuxi Spark’s micro-five-axis machine center produces 98 co-orthopedic implants at a time using a rapid tool change mechanism, reducing Medtronic artificial joints processing cycles from 14 hours to 3.5 hours with a reduction of 72% in lost cut tools. Its nanoscale EDM device achieves flexible switching of 0.8-5.0mm instruments in minimally invasive medical therapy, the surface roughness Ra value is uniform at 0.02μm, and the product qualification rate rises from 88% to 99.6%. According to Johnson & Johnson Medical statistics, the program has boosted the mass production of surgical robot wrist joint parts to 150,000 sets per month, and the unit cost has fallen by 39%.
In consumer electronics, Wuxi Spark’s micro CNC cluster management system realizes collaborative manufacturing of 1,500 devices in Licun Precision, and dynamically adjusts the difference rate of processing load ≤2.3%. The intelligent production line of folding screen hinge by the company facilitates processing 4,800 precision parts in one hour and achieves tolerance compression to ±1.5μm in mass production of HONOR Magic V2, and the yield rate is increased to 99.3%. The AirPods Pro charging contact production line with this technology has a capability of 3.8 million stable output per day, while the overall device efficiency (OEE) is 94.7%, 26 percentage points higher than the conventional solution.
In the manufacturing of energy equipment, Wuxi Spark’s 16MW wind power spindle intelligent production line realizes real-time optimization of processing parameters through digital twin technology, and its processing cycle for one 18-meter long axis is shortened from 72 hours to 26 hours, and its straightness error is less than 0.02mm/m. The company’s main pipeline welding robot cluster system for the national nuclear demonstration project realized synchronous operation of 32 equipment, and weld pass rate reached 99.9% from 96.4%, and the number of manpowers required decreased by 82%. Goldwind Technology application data show that the program has increased wind power gearbox capacity to 4,500 units per year, reducing unit energy consumption by 37%.
In the optical device manufacturing sector, Wuxi Spark ultra-precision machining platform supports mass production from mobile phone lenses to astronomical telescope, collinear machining of Φ2mm-Φ800mm lenses to surface accuracy of λ/50 RMS at Sainty Marine Optical. Its nanoimprint cluster management system provided a stable output of 7200 sets of 8K lenses per hour in mass production of DJI Mavic 3 Pro lenses, refractive index uniformity deviation ≤0.0001%. Zeiss application cases show that the technology has expanded the production scale of optical waveguide components of AR glasses to 1.5 million units per month, and the cost is saved by 58%.
In the industrial Internet sector, Wuxi Spark’s smart factory solution offers 10,000 level device access capabilities through 5G+ edge computing architecture, increasing the device data acquisition frequency from 1Hz to 1kHz in the Bosch Suzhou factory, and reducing the delay of real-time control to 8ms. Schneider Electric’s predictive maintenance system achieved 98.7% warning accuracy in predicting failures, extended the compressor maintenance cycle from 500 hours to 1,800 hours, and reduced downtime loss by 73%. Statistics for Sany Heavy Industry applications report that the program enables collaboration among 38 global production bases during manufacturing, reduces the order delivery cycle by 41%, and raises inventory turnover by 2.3 times.
During the semiconductor packaging and testing, Wuxi Spark’s advanced packaging equipment can switch 12 processes such as QFN, BGA and 3D packaging interchangeably with the quick change wire system, reducing the change time from 6 hours to 18 minutes at JCET. Its own developed wafer-level packaging equipment can maintain the processing capacity of 12-inch wafers up to 320 wafers per hour, and the convex point is extremely uniform with ±0.8μm, thus improving Huawei hisilx 5G chips’ package yield to 99.88%. Ase Group puts the solution at ±35% flexible expansion range of packaging capacity, while the return on investment in equipment is brought down to 2.3 years.
In aerospace, Wuxi Spark’s composite automatic placement machine has enabled continuous production of 16m wingspan wings on COMAC’s C929 program with the use of intelligent path planning algorithms, reducing material wastage by 15% to 1.8%. The company’s established aero engine blade five-axis linkage machining center can accommodate intelligent switching of 9 types of materials, such as titanium alloy and nickel-based superalloy, and can improve the machining efficiency of China Aviation Development Yangtze River 2000 engine blade by 56% and reduce the surface residual stress to 78MPa. According to Boeing’s supplier report, the technology has raised the output of aircraft structural parts to 120,000 units per year and reduced the standard deviation of quality uniformity to 0.03mm.