Developing a Miniature Manipulation Tool via Open-Source Platforms

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In the realm of precision engineering, Diffraction Limited, a company yet to be specifically named in search results, has made a significant stride with the development of a sub-micron capable micro-manipulator. This innovative device showcases remarkable precision and versatility, making it a valuable tool in various small-scale manufacturing applications.

The micro-manipulator, controlled by a Raspberry Pi Pico 2 and three motor drivers, boasts a resolution of about 50 nanometers. Its motor drivers, devoid of internal charge pumps or clocked logic units, are designed to minimize timing errors and motion jitter, ensuring smooth and accurate movements.

Each of the micro-manipulator's three pairs of parallel linkages is actuated by a stepper motor, allowing for a wide range of allowed angles and a movement of 23 mm in each direction. Instead of using flexures, the linkages swivel on ball joints, providing flexibility and durability.

The micro-manipulator's stage is equipped with a magnetic rotary encoder, capable of dividing a single rotation of a magnet into 100,000 steps. To increase the resolution of this encoder, an array of alternating-polarity magnets is attached to the rotor. This setup allows for closed-loop control, ensuring precise and repeatable movements.

One of the micro-manipulator's impressive demonstrations involves its ability to trace a Benchy, a 3D-printed boat model used for testing 3D printers, within a 20-micrometer square when run slowly to reduce thermal drift. This demonstration showcases the micro-manipulator's potential in areas such as micromachining, focus stacking, and maskless lithography.

Diffraction Limited has already put the micro-manipulator to use, potentially coupling an optical fiber with a laser and positioning a chip die under a microscope for testing. The company also has plans to utilise the micro-manipulator for maskless lithography, electrochemical 3D printing, focus stacking, and micromachining.

Another promising small-scale manufacturing approach is the RepRapMicron, but the micro-manipulator developed by Diffraction Limited stands out for its exceptional precision and versatility. Its carrier circuit board, double-sided and using through-hole components for ease of replication, further enhances its accessibility and potential for widespread use.

With its sub-micron precision and versatile design, the micro-manipulator developed by Diffraction Limited is set to make a significant impact in the field of precision engineering and small-scale manufacturing.