This publication is focused on the tool-development for the recently introduced Diamond Micro Chiseling (DMC) process [1]. This process allows the generation of prismatic microstructures at a size between 50 μm and 500 μm, which cannot be manufactured by conventional processes like turning, milling or planning [2]. Prismatic geometries are achieved by using specifically designed V-shaped diamond tools, a special tool kinematics and an ultraprecise 5-axis machine tool. Representative examples of these structures are corner-cube retroreflectors in the abovementioned size. The diamond tool geometry thus represents a significant factor for the feasibility of the process and the obtainable quality of the microstructures. In the design process of the tool's geometry various technical and economical factors have to be taken into account and weighted against contradicting requirements.
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