Micromilling, as described previously, is an emerging fabrication technology with a promising future. It is envisaged as technology of choice to create complex three-dimensional shapes in hard engineering materials, especially for biomedical applications and injection moulds.

However, this requires addressing in the near future, the following challenges that are listed below:

·         Increase the knowledge related to micromachining process parameters for materials different to silicon, e.g. steel, aluminium, ceramics, PMMA, etc., and in consequence, increase micromachined components applications;

·         Improve microtools rigidity in order to reduce premature & unpredictable tool failures, achieve reliable tools on diameters below 100 mm, be able to machine harder materials (innovation regarding different types of coatings) and increase the removal rate [127];

·         Investigate new techniques in diamond cutting process making it more compatible for the machining of ferrous materials, e.g. ultrasonic vibration, carbon rich gas chamber, cryogenically cooled chamber, etc.;

·         Increase the rotational speed of the spindle to achieve recommended cutting speeds and cover a broad range of revolutions with minimum spindle run-out and lengthening;

·         Reduce tool run-out and increase stage positioning precision since it creates drastic changes in the cutting force profile and excessive tolerances;

·         Improve the structural rigidity and reduce the influence of vibrations of the microfactories;

·         Develop specific models for micromilling, considering factors like minimum chip thickness, heterogeneity of the material, ploughing & elastic recovery and different materials;

·         Develop specific CAD/CAM modules for micromilling processes with optimized milling strategies, tights machining tolerances and remaining “micro stocks” recognition;

·         Research on reliable, versatile, economical and practical sensing methods for monitoring and controlling the micromilling process, in particular the employed microtools.