A method of making a brake caliper housing includes providing a first die and a second die that cooperate to define a cavity when disposed against each other along a mating plane. The method further includes introducing molten material into the cavity to cast the brake caliper housing. One or more surfaces of the brake caliper housing may be machined.

Described herein is a first method of forming a hole in a workpiece, having a first surface and a second surface opposite the first surface. The method includes forming a first hole, having a first diameter, in the workpiece by passing a first cutter through the workpiece from the first surface to the second surface. Additionally, the method includes forming a chamfer in the second surface of the workpiece concentric with the first hole using a second cutter. The chamfer has a second diameter larger than the first diameter. The method further includes forming a second hole, having a third diameter larger than the first diameter, in the workpiece concentric with the first hole by passing a third cutter through the workpiece from the first surface to the second surface.

A universal bellhousing which may be adapted to a variety of automotive engine and transmission combinations and method of making the same is disclosed. The bellhousing is made by spin forming a sheet of material and welding a transmission plate onto the cone. The cone and transmission plate are indexed to mount to a specified engine-transmission combination.

A gas flow can be provided together with a liquid jet guided laser beam to remove accumulated liquid on the processing surface. The gas flow can be configured to have minimum interference with the liquid jet guided laser beam, while functions to blow away liquid generated by the liquid jet. Keeping the surface free from accumulated liquid can improve the efficiency of the liquid jet guided laser processing.

A flow directing apparatus for directing fluid flow includes a flow body defining a bore therethrough configured and adapted to direct fluid flowing therethrough. The bore includes an outlet and an opposed inlet with an enlargement, formed as a countersink and/or a chamfer using a suitable boring device. The enlargement is configured and adapted to reduce sensitivity to entrance-edge conditions for the bore.

Embodiments of a method of depositing a thin film on a substrate is provided that includes placing a substrate on a substrate support that is mounted in a processing region of a processing chamber, flowing a process fluid through a plurality of gas passages in a diffuser plate toward the substrate supported on the substrate support, wherein the diffuser plate has an upstream side and a downstream side and the downstream side has a substantially concave curvature, and each of the gas passages are formed between the upstream side and the downstream side, and creating a plasma between the downstream side of the diffuser plate and the substrate support.

A gas flow can be provided together with a liquid jet guided laser beam to remove accumulated liquid on the processing surface. The gas flow can have minimum interference with the liquid jet guided laser beam, while functions to blow away liquid generated by the liquid jet. Keeping the surface free from accumulated liquid can improve the efficiency of the liquid jet guided laser processing.

A tire mold or a tire mold segment can include an air compression cavity, which connects to multiple surface connection slots having dimensions between 10 and 300 microns, which can be suitable for selective removal of air in the mold. The air compression cavity, can be close to the outside ambient, allowing the air escaping the interior of the mold to be compressed, which can assist in preventing the rubber material from leaving the mold pattern surface.

A liquid-jet-guided laser system can be used to generate functional slots having different depth and sidewall profiles by applying active control of laser beam parameters. Blinds slots can be processed onto a workpiece, such as a tire mold or a turbine vane, for an insertion of a sipe or a sealing element, respectively. Through slots can also be processed onto a workpiece, such as a turbine element for cooling during operation or a semiconductor wafer for singulation purpose. The processing of the workpiece can include a two-step procedure, wherein the first step comprises a pre-cut. The pre-cut cuts a contour outline of a slot onto a workpiece corresponding to an element that is to be inserted into the slot. The second step comprises a removal cut to remove excess workpiece material in between the contour outline. The liquid-jet-guided laser system can employ multiple-wavelength processing of a multiple-material workpiece.

Embodiments of a gas diffuser plate for distributing gas in a processing chamber are provided. The gas distribution plate includes a diffuser plate having an upstream side and a downstream side, and a plurality of gas passages passing between the upstream and downstream sides of the diffuser plate. The gas passages include hollow cathode cavities at the downstream side to enhance plasma ionization. The depths, the diameters, the surface area and density of hollow cathode cavities of the gas passages that extend to the downstream end can be gradually increased from the center to the edge of the diffuser plate to improve the film thickness and property uniformity across the substrate. The increasing diameters, depths and surface areas from the center to the edge of the diffuser plate can be created by bending the diffuser plate toward downstream side, followed by machining out the convex downstream side. Bending the diffuser plate can be accomplished by a thermal process or a vacuum process. The increasing diameters, depths and surface areas from the center to the edge of the diffuser plate can also be created computer numerically controlled machining. Diffuser plates with gradually increasing diameters, depths and surface areas of the hollow cathode cavities from the center to the edge of the diffuser plate have been shown to produce improved uniformities of film thickness and film properties.