Artikel ALIO Industries, LLC

In general — and indeed perhaps exacerbated by the disruption caused by the recent pandemic — manufacturers need automated processes to boost productivity and speed products to market in order to remain competitive. Production machinery also needs to be ultra-reliable and operate at the required capacity. At the heart of such automated processes is reliable and repeatable motion control which is critical for keeping production lines operating optimally, and in turn reducing lost time due to manual intervention.

ALIO Industries has been at the vanguard of innovation in nanometer-level precision motion control solutions for over 20 years, and is a specialist in the area of development of motion control systems for industrial automation and manufacturing. The company advocates that designers when specifying motion control for their specific applications, do not feel forced to choose the least expensive solution for the application as it exists today, but choose a system that operates optimally as application requirements change and evolve over time.

Peter Lehner, Sales & Marketing Director at ALIO says, “When specifying a motion control solution for exacting industrial manufacturing applications, beyond an analysis of the specific functionality of a particular system, it is also of vital importance to analyse how an application is likely to develop in the medium to long-term (i.e what new functionality or sub-systems will be required over time) and, for example, what space constraints that may dictate system architecture and component choice. A snap decision when specifying a motion control solution may be costly later in the product development process. There are some common mistakes. First, and most common, a motion control solution is specified without enough focus on the end application. Often, the motion control system is selected first, either from a supplier that is familiar, or one that seems to have all the latest bells and whistles. Choosing the motion control system first can lead to the use of components not ideal for the end application, and workarounds to get a system to work correctly which increases development time and costs. Also, without an eye on the future, a hastily chosen motion control system will limit new functionality, and while choosing the least expensive solution may seem prudent in the short term, in the medium to long-term it can severely impact ROI.”

ALIO Industries has developed a sophisticated product configurator on its website to allow customers to put in headline application requirements, and be presented with viable motion control solutions which cover present and future application requirements. The product configurator allows ALIO customers the ability to specify the basic motion control requirements that are available in the standard ALIO portfolio, and to apply ALIO’s support and experience to optimize the motion control recipe ensuring a perfect application specific fit. So if users know the direction of motion required; the basic product type (i.e. linear motion, z-lift vertical stages etc.); application specific needs (i.e. smooth continuous movement, step and settle etc.); open center or closed; travel range; maximum weight of payload; level of bi-directional repeatability; and the environment the application is to be used in (ambient, cleanroom, or vacuum); the product configurator will display ALIO’s relevant options.

Lehner concludes, “Our product configurator (coupled with our unrivalled expertise in the area of nanometer-level precision motion control), means that we fully understand that achieving competitive advantage in exacting specialized industrial manufacturing scenarios requires the use of the right motion control tools. Take a look at the production of top-notch motors using electromagnetic components. In such a scenario, an efficient coil with a high fill factor minimizes not only the amount of material and volume required for a given linear motor, wound electromagnetic component, or sub-component, but simultaneously improves the heat conductivity of the winding. Instant in-process, sub-micron corrections of the product during manufacture (such as during the winding process for an electromagnetic motor) help to optimize components and drive innovation. In ultra-high-end industries like this, it is vital to use the best quality motion control products available, and to have available highly-customizable products and processes. ALIO’s precision linear X, linear Z and rotary stages enable specialized manufacturing as a fully integrated, value-adding feature that utilizes advanced systems at a competitive cost point allowing practical customization and an overall increase in product quality.”

ALIO Industries (an Allied Motion company) has a 20-year plus history working at the vanguard of nanometer-level precision motion control, which makes it a highly intuitive player in the sector. The company’s history is characterized by the introduction of bleeding edge and innovative nanometer precision motion control innovations, and founder Bill Hennessey is driven by the goal of providing motion control solutions that stimulate product innovation and cater for the most demanding applications in the market.

In keeping with this goal, ALIO is today proud to announce the launch of a new website which contextualizes ALIO’s numerous motion control solutions within the industrial sectors and applications where they are most used and most appropriate. In addition, the company also launches its new product configurator, which allows users to enter key application-specific requirements and then be presented with motion control solutions that perfectly match these requirements.

Peter Lehner, Director of Sales & Marketing at ALIO says, “After a lot of time and effort we are pleased to launch our new product configurator which is at the heart of our new website. The overarching goal of all the web development work we have just undertaken, and the introduction of the product configurator, is to put our customers at the heart of what we do. We are the motion control experts in the room, and while our customers have a view on what they may need in terms of motion solutions, the information and functionality on our website has to be geared to our customers. Using the analogy of a car, customers need to know it will get them from A to B, they do not need to know in intricate detail how. The same with precision motion control. Our highly intuitive product configurator allows customers to put in headline application requirements, and be presented with viable solutions. So if users know the direction of motion required; the basic product type (i.e. linear motion, z-lift vertical stages etc.); application specific needs (i.e. smooth continuous movement, step and settle etc.); open center or closed; travel range; maximum weight of payload; level of bi-directional repeatability; and the environment the application is to be used in (ambient, cleanroom, or vacuum); the product configurator will display ALIO’s relevant options with each application requirement displayed graded best fit, good fit, or just fit. This is a major step forward for customers looking to specify motion control options, and we invite anyone with an interest to try it today.”

ALIO offers what is often described as a “high-end boutique-like service” from its world-class facilities in Colorado, USA. While providing an extensive range of off- the-shelf products — including Hexapod robotic systems, air bearing systems, and linear and rotary nano-precision systems (with both mechanical and air bearings guides) — the company also customizes solutions, using its experience to create innovative cutting-edge motion control systems for specific customer applications. Due to the modularity of ALIO’s systems, not everything needs to be designed from scratch, and the experience of the ALIO team coupled with this modular design concept means fast and reliable adaptations can be made to suit the specifics of particular applications

To achieve the precision and quality that its customers demand, ALIO makes everything under one roof in its state-of-the-art advanced machine shop, using cutting-edge technologies in controlled environments to ensure the production of optimized motion control solutions. ALIO has 100%-part verification which is unique in the motion control industry.

With design, machining, metrology, manufacturing, and assembly teams all working together, ALIO nurtures cross-company collaboration every day. This allows the company to be flexible and nimble as we work with its customers to provide the ultimate in high quality ultra-precise solutions. Lehner concludes, “Where other companies see obstacles and problems, ALIO sees opportunities and solutions, and this attitude is what led to the creation of the product configurator. Precision motion control is inherently complicated, and creating motion control systems able to achieve nanometer-level tolerances repeatably is difficult, which is why there are so few companies capable of achieving it. But customers are only interested in whether a solution is fit for purpose, can achieve the tolerances required, at a cost that fits budget. This is where the product configurator is so powerful, as it presents viable options without the user having to have an in-depth understanding of motion contol, but also gives users the ability to play around with the requirement for different attributes to see best-fit solutions. Effectively through our new pragmatically presented website and product configurator we are lighting up the area of motion control, and by so doing illuminating the path for customers to speedily select optimized motion control solutions.”

Precision motion control plays a crucial role in optics testing and assembly by ensuring precise and accurate movement of optical components during the testing and assembly process. This helps to achieve high accuracy and repeatability in testing results and ensures proper alignment and positioning of components for optimal performance in assembled optical systems. ALIO Industries’ precision motion control systems provide precise and controlled movement of optical components in X, Y, Z dimensions, and rotation, allowing for precise manipulation and measurement of optical elements.

Bill Hennessey, President of ALIO Industries says, “Camera array modules, translational OIS, telescopic integrated lenses for miniature cameras (used in everyday products like cell phone cameras and drones) all consist of various lenses. The industry trend is towards higher resolution 4K and 8K lenses in smaller and smaller areas, requiring increased precision in all 6 motion axes to achieve these combined objectives. Precise positioning of each lens is crucial for sharp, distortion-free images. As all lenses have different diameters, a highly flexible system with multiple tool-center points is needed allowing the various components to be handled precisely and reliable, thereby cutting down tool costs, production time, and scrap. For such applications, ALIO has developed the MINI Hybrid Hexapod® which is ideal for automated lens and camera alignment/bonding to CCD arrays. Any application requiring 6-degrees of freedom positioning with nanometer/arc-sec levels of incremental motion and repeatability is a good fit for this motion control system where product sensor resolution improvements are driving the need for higher precision.”

The MINI Hybrid Hexapod® developed by ALIO Industries is a precision motion control solution that combines the stability and accuracy of a traditional hexapod with the agility and flexibility of a gantry system. This makes it a suitable solution for optical testing and assembly, where precise positioning and alignment of optical components is required.

The MINI Hybrid Hexapod® provides high accuracy and stability, fast and precise motion, and flexible positioning, making it a versatile tool for a variety of applications.

Currently the smallest of ALIO’s Hybrid Hexapod® line, the MINI is compact but still provides a 54,000 mm2 working volume (60x60x15mm). With the flexibility to scale tripod, rotary and monolithic XY, customers can size the MINI to their required working volume. Brakes, gear reduction, ball screw drive, and linear motor drive are some of the options to match the performance to specific applications.

The MINI Hybrid Hexapod® is ideal for automated lens alignment or bonding processes. It has been helpful in building camera array modules, translational OIS, and telescopic integrated lenses for miniature cameras used in every-day products like cell phone cameras and drones. Any application requiring six degrees of freedom (6-DOF) positioning with nanometer/arc-sec levels of incremental motion and repeatability is a good fit for this product. ALIO Industries is a manufacturer of precision motion systems and custom automation solutions. In addition to the MINI Hybrid Hexapod® the company offers a range of off-the-shelf solutions for optical component testing and assembly, and can even provide custom solutions for specific requirements and applications.

Laser inscription is a rapidly growing field and an important component of many industrial production processes. In order to achieve the most precise results, repeatably precise motion control systems are essential. These systems provide the exact positioning accuracy and speed needed to keep up with the demands of high-volume and high-precision laser inscription applications. However, not all motion control systems are created equal.

Having recognized that most laser marking systems are restricted to operating in two-dimensions, and can therefore only scan on the and x and y axes (and in addition also lack the ability to process materials that have a high hardness of low ignition point) ALIO created a range of multi-dimensional motion control systems ideal for demanding inscription applications.

Bill Hennessey, President of ALIO Industries says, “There are several drawbacks to using a laser inscription motion control system that only works in two dimensions. First, the system is limited in the types of objects it can engrave or cut. Basically, it can only add inscriptions to surfaces facing the marking system, so objects with complex shapes or raised surfaces cannot be engraved with the precision and therefore the quality needed by many customers. Second, 2D systems are also limited in the height of features they can engrave or cut. In addition, 2D systems are also limited in the accuracy of the engraving, as the laser beam is not always able to follow the contours of an object accurately, so the inscription may not be precise.”

A particular and important application is the inscription of diamonds. Without causing any damage, a micro-laser beam is used to etch a microscopic inscription on the girdle of diamonds. The often complex shapes of diamonds mean that 2D inscription machines struggle to provide neat engravings. The need for a 3D or 3D+ solution that is at the same time speedy, precise and repeatable is obvious. Such a solution would also after initial capital outlay save money by reducing the potential for scrap and through improved inscription quality reduce the need for costly post-processing.

There are many reasons why 3D and 3D+ motion control systems are superior for laser inscription applications. For one, they allow for more precise and accurate laser beam positioning, using as they do a three-dimensional axes of movement, which means that the laser beam can be positioned more precisely on the surface of the material being inscribed.

Another reason is that they offer a greater degree of flexibility in terms of the size and shape of the inscribed area, there being no limitations, as the laser beam can be moved freely in three-dimensional space. This allows for much larger and more complex inscribed shapes and designs.

Finally, they also offer a higher degree of speed and efficiency in terms of inscription. With a high quality 3D or 3D+ motion control system the motion profile is optimized promoting straight parallel movements, and ‘real’ corners rather than curves.

Hennessey concludes, “To overcome the limitations of traditional 2D inscription machines, ALIO has developed compact x, y, z motion control systems, gimbal systems with up to 5 axis, and Hybrid Hexapods® that exhibit smooth travel, high stiffness, and low dither which all enhance the clarity and versatility of the inscription. Our compact x,y,z motion control systems are designed to provide high performance and precise positioning capabilities in a small footprint. Gimbals and Hybrid Hexapods® are meant to maximize flexibility, and improve quality on complex forms and hidden spots. These systems utilize precision motors for each axis of travel, providing high thrust force and low inertia for rapid acceleration and deceleration. Integrated position feedback sensors ensure precise positioning and repeatability, while programmable motion controllers allow for custom movement profiles to be created. They are ideally suited to laser inscription applications where fast and precise motion control is required in a limited space.”

Digital pathology instruments are important tools in modern medicine, allowing for the digitization of slides and images, which can be stored, shared, and analyzed more easily than with traditional microscopes.

Digital pathology offers a number of patient and efficiency benefits. For patients — due to high throughput and high speed — it reduces waiting times, provides more precise diagnosis, and can obviously stimulate faster treatment with all this implies in terms of better clinical outcomes.

In terms of efficiency, the nature of the process also enhances the quality of the pathology work-flow. Digital pathology is more accurate and quicker than microscopy, prior case data can be speedily accessed, and data storage allows for long-term predictive analytics. In addition, the sophisticated nature of digital pathology instruments means the ability to offer live zoom and multiple angle views, and the ability to measure multiple areas of interest. All this improves productivity in the short-and long-term.

Digital pathology is driven by ultra-accurate and repeatable motion control systems, and ALIO Industries is proudly providing next-generation motion control solutions to the sector thereby advancing the speed and accuracy of imaging machines.

Bill Hennessey, President ALIO Industries says, “Our stages are perfect for the high-speed, high-quality scanning or imaging necessary for digital pathology. Offering solutions bespoke to the respective instrument’s architecture, we ensure that the final digital pathology instrument occupies minimal space in any laboratory or clinic situation. When scanning slides under a static microscope or camera, an XY(Z) motion control stage shifts the slides to capture images. For this to be effective, image capture must take place quickly and accurately meaning a motion control solution with smoothness (ensuring high resolution images), flatness (ensuring proper z-axis focus), and straightness (reducing overlap between scanning passes while increasing productivity).”

The ability of ALIO stages to move straighter than any other stage on the market means that they allow the production of data with higher resolution and accuracy than from any other motion control supplier. The company offers numerous off-the-shelf options but stages are also customizable, meaning that ALIO can work in partnership with digital pathology providers at the design stage of process development, achieving the most efficient motion control solutions for specific customer applications.

Hennessey continues, “To ensure accurate and complete tissue sample analysis, high bi-directional repeatability to target small tissue areas is needed. ALIO provides monolithic, low-profile, open-center X, Y, Z electromagnetic driven stages for such applications, promoting high speed, high throughput, and low friction in a small footprint, scan times being reduced allowing better pre-scan images. Digital pathology is all about parallel paths or a serpentine motion to capture all the data points. ALIO is novel in that our straightness is superior to all other motion control options for this application. This promotes the compiling of data in one pass impossible if stages cannot move parallel with less than 2-3 micron variation. This also make for more precise data since it does not need to be calculated by 6 sigma algorithms that are necessary to get a result from poor motion performance. “

The future of digital pathology is very exciting. As more pathologists adopt this technology, ALIO will continue to innovative new motion control solutions that make digital pathology machines even more efficient and effective.

(March 28th, 2023, Arvada, CO, USA) Genome sequencing is a powerful tool that can help unlock many secrets about both the natural world and the human body. As the demand for faster, more accurate genome sequencing increases, so does the need for ultra-precise motion control systems which are critical for ensuring that the sequencing process is as efficient and accurate as possible.

Ultra-precise motion control systems provide the high levels of accuracy and speed required for genome sequencing applications. By using these systems, genome sequencing can be performed more quickly and with greater accuracy than ever before. This is essential for ensuring that the results of genome sequencing are as accurate and reliable as possible.

Bill Hennessey says, “Motion control systems are driving the field of genome sequencing, which is bedevilled by high cost and low throughput issues, and the problem of handling massive data sets.

Automation is a particularly challenging element in the complex instrumentation used, but has played a vital role in genome sequencing, from the development of automated DNA sequencing machines to the use of robotic systems for sample preparation. Automation has helped to speed up the process of genome sequencing and has made it possible to sequence larger genomes more accurately and cost-effectively.

ALIO promotes increased throughput, reduced run time, and lower costs per run coupled with high quality and repeatable imaging by creating a smoother, continuous scan process using a monolithic XY stage and a low friction vertical Z-stage for focusing.

Z focusing can compensate for both variation in the sample and the flatness variation of the XY stage. The ideal technology for achieving the optimum move and settle time is a linear motor stage with a magnetic counterbalance. The linear motor allows for maximum acceleration and deceleration and provides exceptional position stability.

For genome sequencing, where even minor variations in the stage velocity or drift of the trigger clock can cause poor imaging, ALIO is renowned for providing market-leading motion control solutions. 

Hennessey continues, “At ALIO we are aware that motion control systems are critical enabling technologies for genome sequencing applications because they allow for precise and accurate movements of the sequencing equipment. This is essential for ensuring that the sequencing process is performed correctly and producing accurate results. They provide accuracy and precision to the process by ensuring that samples are handled correctly and efficiently. Additionally, larger travel ranges allow more samples in the system at one time, and this means the system requires less opening, which reduces the chance of contamination and reduces down times. By utilizing ALIO’s advanced motion control technologies, researchers can achieve significant cost savings while delivering reliable results with greater precision than ever before.”

The future of genome sequencing is incredibly exciting and to a large extent is driven by ever-more sophisticated DNA sequencing technologies. ALIO remains focused on ensuring that the motion control systems it develops for genome sequencing are consistently rapid, accurate and affordable. In this way, the company is proud to help scientists unlock previously hidden secrets about the genetic code of life on Earth, the biology of disease, and the development of new treatments and diagnostic tests. 

(April 18th 2023, Arvada, CO, USA) Accurate motion control is crucial in manufacturing medical and clinical devices like diagnostic imaging machines and video endoscopes. Even the slightest deviation from specifications can make a device less effective or even hazardous. To ensure the highest quality and safety standards, manufacturers must invest in precise and dependable motion control technology. This guarantees optimal results for patients using their products.

ALIO provides the AngularesTM Hybrid Hexapod® for such applications, which accommodates large XY movement to shift the instrument from process step to process step, there being 6 axis movement at every process step without the need of manually moving the instrument or using an additional robot to handle components. The AngularesTM exhibits low friction, low particle generation, is easy to access and clean, and maintains the highest precision. Highly flexible programming enables 4K (and beyond) image quality even using the tiniest and angled endoscopes thanks to the unique ranges of the system.

Bill Hennessey, President of ALIO says, “The 60-degree tip/tilt travel of the AngularesTM Hybrid Hexapod® is by far the most angular travel range available from any 6-Degree-Of-Freedom (6-DOF) positioner on the market and offers the same unmatched positioning performance found in any of ALIO’s full-line of Hybrid Hexapod systems. The AngularesTM features precision crossed roller bearing guides, optical incremental or absolute encoder feedback on all axes, linear motor and/or servo ball screw drives, unlimited programmable tool center point locations and coordinate offsets, and zero backlash on all axes. The design makes the AngularesTM capable of unlimited XY travel, Z travel for 62 mm which can be increased to 208 mm using other tripod models, tip/tilt travel of 60 degrees (+/- 30 degrees) with continuous 360 degree Theta-Z, XYZ bidirectional repeatability of less than +/- 0.6 arc-seconds, velocity up to 100 mm/second XY and Z, and less than 10 nanometers linear and 0.1 arc-seconds angular minimum incremental motion.”

The AngularesTM is part of the Hybrid Hexapod family of motion control systems produced by ALIO, the Hybrid Hexapod itself being developed to address the inherent performance limitations of conventional hexapods. ALIO’s patented 6-DOF design seamlessly blends and takes advantage of the strengths of serial and parallel kinematic structures while avoiding their weaknesses. The Hybrid Hexapod offers far greater functional versatility, nanometer-level accuracy, repeatability, and superior 6-DOF trajectories than is possible with any traditional hexapod or stacked stage configuration.

Hennessey continues, “Standard hexapods satisfactorily service applications where micron motion tolerances are required, but as the demand for nanometer requirements expands, standard hexapods struggle. This is because there are performance limitations inherent in all ‘conventional’ hexapod designs. They operate within 3-dimensional space, and have errors in all 6 DOF. However, hexapod motion systems have typically only been characterized by performance data of a single degree of freedom. This practice leaves error sources unaccounted for in several degrees of freedom, especially in the areas of flatness and straightness, which are critical precision needs at the nanometer-level required in many medical and clinical devices.”

The unique design of the Hybrid Hexapod® is comprised of a parallel kinematic tripod to deliver Z plane and tip/tilt motion. This tripod is integrated with a monolithic serial kinematic stage for XY planar motion. A rotary stage integrated into the top of the tripod (or beneath depending on application needs) provides 360- degree continuous (Theta-Z) rotation. In this hybrid design, individual axes can be customized to provide XY travel ranges from millimeters to virtually unlimited ranges while maintaining nanometer-levels of precision. Novel forward and inverse controller kinematics provide an unlimited number of programmable tool center point locations plus unmatched path precision and performance.

The 60 degree tip/tilt travel of the AngularesTM Hybrid Hexapod®, by far the most angular travel range available from any 6-DOF positioner on the market, in addition to providing an ideal motion control system for an array of medical and clinical device applications is also perfectly suited for aspheric and freeform optical metrology, silicon photonics packaging and probing, laser micro processing (non-planar substrates and taper control), wafer metrology, camera module alignment and assembly, sensor/image stabilization testing, and optical element and fiber alignment.

(May 9th 2023, Arvada, CO, USA) ALIO Industries recognizes the challenges associated with testing micro-LED chips, and maintains that precision stages can be a crucial tool in the testing process as they provide the precise positioning and motion control necessary to achieve accuracy and repeatability.

A micro-LED chip is a type of light-emitting diode that is significantly smaller than traditional LEDs, and can be used in a variety of applications, including displays, lighting, and sensing.

One of the main advantages of micro-LEDs is their high brightness and efficiency. They can emit a lot of light using a relatively small amount of power, which makes them energy-efficient and long-lasting. Additionally, micro-LEDs can be used to create highly customizable displays with excellent color accuracy and contrast.

However, micro-LED technology is still relatively new and can be expensive to produce compared to traditional LED technology. Moreover, the testing and manufacturing of micro-LEDs require highly precise equipment and processes due to their small size, which can be a challenge for manufacturers.

Bill Hennessey, President of ALIO picks up the story. “As the micro-LED market gears up for mass production, the focus is shifting to the two major challenges that slow down commercialization — low yield and high cost. Since the chip size of micro LEDs can be as small as a single micron, existing inspection equipment is often inadequate in many respects. Many standard tools simply don’t provide high enough resolution. Moreover, with the smaller pixel sizes, there is also a dramatic rise in the number of pixels that need to be processed during inspection. Test technologies are therefore emerging such as electroluminescence (EL) which is able to identify a great number of defects.”

EL testing is a non-destructive method of testing micro-LEDs and other semiconductor devices, which involves passing a small electrical current through the device, which causes it to emit light. The emitted light can then be measured and analyzed to determine the quality and performance of the device.

EL testing is particularly useful for testing micro-LEDs because it allows for the detection of defects and performance issues that may not be visible using other testing methods. For example, EL testing can detect small defects in the micro-LED structure that may be invisible to the naked eye, such as dislocations or disclinations. Additionally, EL testing can provide information about the uniformity of the device’s emission and the distribution of current within the device.

The EL testing process requires physical probing of the electrical contacts on the micro-LED chips, which must be done with extremely high precision to avoid damage to the devices.

The smaller pixel sizes of micro-LEDs mean that there is a significant increase in the number of pixels that need to be processed during inspection, which makes high-throughput inspection a major challenge. Precision motion control solutions can help to optimize the speed and efficiency of the testing process, enabling rapid and accurate movement of the testing equipment and reducing the time and cost associated with testing large numbers of micro-LED chips.

“ALIO has decades of experience delivering highly repeatable stages with unrivalled point precision®, reaching the “point of interest” in testing within a few nanometers ensuring micro-LED chips don’t get damaged during the EL test,” Hennessey continues. “We offer several motion control technologies that are suitable for testing micro-LEDs. For example, there is the Hybrid Hexapod®, a parallel kinematic motion control system that provides six degrees of freedom with sub-micron precision and repeatability. This technology is ideal for micro-LED testing applications requiring high precision, accuracy, and speed. The Hybrid Hexapod® combines rotary and linear motion to provide a large range of motion and high load capacity, making it suitable for testing large numbers of micro-LEDs simultaneously.”

Also, there are ALIO’s Air Bearing Stages, linear motion control systems that provide frictionless motion with high precision and accuracy. This technology is suitable for micro-LED testing applications that require high-speed and accurate motion control. Air bearing stages are capable of achieving nanometer-level positioning accuracy and repeatability, making them ideal for testing micro-LEDs with high resolution and accuracy.

See the array of motion control options that are available for micro-LED inspection from ALIO HERE, or specific requirements can be plugged into the company’s PRODUCT CONFIGURATOR to see the most suitable motion control solutions.

(May 26th 2023, Arvada, CO, USA) The demand for nanometer-capable stages is increasing exponentially as the trend to achieve greater precision and control in metrology and Nano Metrology applications continues.

With the advent of cutting-edge sensor technologies, measurement capabilities have become increasingly sensitive, enabling the detection and characterization of minute features and deviations in samples. To leverage the full potential of these advanced sensors, it is essential to have motion control stages that can move the samples or sensors with extreme precision and stability.

The ability to traverse several hundred millimeters while maintaining nanometer-level accuracy opens up new possibilities for research, quality control, and manufacturing processes that require intricate measurements and fine adjustments. As a result, the development of nanometer-capable stages has become crucial to meet the demands of modern metrology and unlock further advancements in various industries.

Any inaccuracies or errors in the motion can significantly affect the measurement results. Even minor deviations or vibrations during the movement of the sensors can introduce unwanted noise and artifacts, compromising the overall accuracy of the measurements.

“To overcome this challenge, motion systems must be engineered with exceptional precision and stability. They need to be capable of achieving sub-nanometer resolution and maintaining tight tolerances throughout the entire range of motion. By surpassing the accuracy of the sensors, these high-precision motion systems ensure that the measurements obtained are not limited or compromised by the motion itself, enabling researchers and industries to achieve the highest level of measurement accuracy possible,” explains ALIO Industries President Bill Hennessey

For such applications, ALIO provides its vertical Z-stages and monolithic XY bases. ALIO’s Z-stages stands out with their innovative design, offering a vertical solution that is completely linear-based and delivers performance comparable to air-bearing systems.

Hennessey continues, “What sets ALIO’s Z-stage apart is its exceptional precision, surpassing traditional Z-wedge solutions by an order of magnitude. This means that our Z-stage can achieve unparalleled levels of accuracy and stability in vertical positioning applications.”

By eliminating the drawbacks associated with traditional Z-wedge mechanisms, such as non-linearity and mechanical hysteresis, ALIO’s unique design ensures consistent and reliable vertical movement with sub-nanometer resolution, opening up new possibilities for nano-metrology applications and nanotechnology, semiconductor manufacturing, and optics manufacturing, enabling OEMs to achieve levels of performance that were previously unattainable with conventional solutions.

Using a vertical Z-stage on a monolithic XY base allows the customer’s payload to be mounted directly on the top of the stage in-line with the motor, encoder, bearings, and counterbalance, thus minimizing overhanging brackets and greatly reducing potential Abbé errors (optical distortions that occur due to the variation in focal lengths for different wavelengths of light, resulting in color fringing and reduced image sharpness).

ALIO’s XY monolithic stages introduce previously unheard-of straightness and flatness of travel with nanometer precision to reduce measurement uncertainty for metrology OEMs, ensuring more precise and reliable measurement data, which is crucial for quality control, research, and next generation manufacturing processes.

(June 5th 2023, Arvada, CO, USA) Additive manufacturing (AM) is crucial for manufacturers today because it enables the production of highly complex and customized parts that are difficult or impossible to achieve with traditional manufacturing methods. It offers increased design freedom, faster prototyping, reduced material waste, and the ability to create on-demand, decentralized production networks, all of which contribute to enhanced efficiency and competitiveness in the modern manufacturing landscape. AM has long disrupted the prototyping stage of product development, but recent advances in speed of operation, improved materials, and optimization software, now see AM becoming a disruptive force in production scenarios.

High-end, precise motion control systems are critical for the accuracy of additive manufacturing (AM) technologies due to their ability to deliver precise and coordinated movements of components. In AM, layer-by-layer deposition or selective laser sintering/melting requires precise control over the motion of the build platform, printhead, or laser. The accuracy of these movements directly affects the final dimensional accuracy and quality of the printed parts. With the right motion control systems, manufacturers can achieve tight tolerances, ensuring that each layer is accurately positioned and aligned, resulting in precise geometries and dimensional accuracy.

“Furthermore, precise motion control systems play a crucial role in minimizing errors, defects, and inconsistencies in the AM process”, says President of ALIO Industries Bill Hennessey. “Any deviations or inaccuracies in the motion can lead to misalignment, overextrusion, or insufficient material deposition, compromising the integrity and quality of the printed parts. High-end motion control systems offer advanced feedback mechanisms, such as encoders or sensors, that provide real-time position feedback to the control system. This feedback enables closed-loop control, allowing for immediate adjustments and corrections during the printing process, thereby ensuring accurate and consistent deposition of material layer by layer.”

As AM transitions from a prototype to a production technology, the importance of precise motion control solutions increases significantly. In prototyping, the focus is often on creating functional proofs-of-concept or small-scale models, where tolerances and accuracy requirements may be more relaxed. However, as AM evolves into a production technology, the need for precise motion control becomes paramount.

In production-scale AM, there is a higher demand for consistent and repeatable quality across large quantities of parts. Precise motion control ensures that each layer is accurately positioned, minimizing dimensional variations and maintaining the desired geometries throughout the production process. This level of control becomes crucial in achieving tight tolerances and dimensional accuracy, which is essential for meeting the specifications and requirements of end-use parts.

Moreover, precise motion control solutions play a vital role in optimizing production efficiency. As AM is adopted for production applications, speed and productivity become key factors. Precise control over the motion of components allows for optimized path planning, reduced unnecessary movements, and faster deposition rates. This increased efficiency leads to higher throughput and cost-effectiveness in production scenarios. Hennessey concludes, “ALIO Industries serves as a crucial one-stop-shop for all positioning requirements in AM applications, offering a comprehensive range of motion solutions. Our diverse portfolio, including XY-stages, 6D Hybrid Hexapods, gantries, and fully assembled motion solutions, caters to the varied needs of AM practitioners, simplifying the selection and integration process. By providing a single source for positioning components, ALIO streamlines procurement, ensures compatibility, and facilitates technical support, ultimately enhancing operational efficiency and reliability for AM system developers and operators.”

Peter Lehner, Director of Sales and Marketing at ALIO says, “Most of the demand for cleanroom manufacturing is driven by customers in the semiconductor, micro-electronics, and medical industries. Our new cleanroom not only enables contamination control, ensuring the production environment has minimal airborne particles that could compromise product quality (critical for industries that demand high levels of cleanliness to prevent defects or failures in motion control devices), but it also maintains process consistency by offering controlled conditions. The cleanroom simplifies adherence to industry expectations, standards and regulations, and also instills customer confidence by showcasing our commitment to quality, precision, and customer satisfaction for which ALIO is renowned.”

The cleanroom is another in a series of significant investments undertaken by ALIO which also includes on-going investment in maintaining and optimizing its metrology lab and equipment, allowing the company to guarantee the unique one-of-a-kind nanometer-level precision attainment for which it is world famous.

Bryan McCloskey, Operations Manager at ALIO says, “The continuous investment into lean manufacturing principles, our new cleanroom, and our growing metrology lab demonstrates our commitment to quality, cleanliness, and precision. Customers can trust our consistent and reliable products, innovative approach, adherence to standards, and long-term partnership potential, making them confident in receiving the highest-quality motion control solutions.”

(Arvada, CO, USA, 15th August 2023) ALIO Industries – an Allied Motion Company — acknowledges the publication of the ASME B5.64 standard “Methods for the Performance Evaluation of Single Axis Linear Positioning Systems” last week as a significant step in the redefinition of measurement of precision in motion systems, something that as a company ALIO has been championing for over a decade.

The ASME standard suggests that when it comes to defining the precision of ultra-precise single axis linear motion systems such as those produced by ALIO, companies should move away from conventional planar methodologies, and towards 6D point precision specifications.

Bill Hennessey, President of ALIO picks up the story, “When analyzing motion control solutions that provide sub-micron and nanometer-level accuracy, ALIO has contended for a number of years that a new language is necessary, and new standards are required to indicate the real levels of precision that different motion control solutions can achieve. So saying, nearly 12 years ago, ALIO trademarked the phrases Point Precision® and 6D Point Precision® to protect its position in the market.

All motion systems operate in 3-dimensional space and have errors in 6 degrees of freedom (6-DOF). However, motion systems are often only characterized by performance data of a single or subset of these 6-DOF. This practice leaves several error sources unaccounted for in performance data and specifications. ALIO has contended for a considerable amount of time that repeatability performance for metrology inspection and manufacturing systems must be analyzed and specified using a “point repeatability” method that accounts for 6D spatial errors in order to provide true representation of nanometer-precision performance. The recent publication of ASME B5.64 shows that standards agencies also see the value behind this methodology.

Historically, specifying repeatability as a single number representing the variation in linear displacement along an axis of travel, i.e. plane repeatability was valid as the repeatability specifications were large enough that other error factors were only a small percentage of the total error and could be ignored. However, this test method makes a critical assumption, namely that the plane only moves in one dimension and the axis is perfectly straight. At the nanometer-level, this assumption is not realistic.

The new ASME standard recognizes that in nanometer-level precision systems, ‘other’ errors that were previously ignored in less accurate systems often become equal to or greater contributors to the 6D repeatability performance. At the nanometer-level, the axis of travel should actually be shown as bending and twisting through three-dimensional space and thus plane visualization becomes meaningless as it will tip, tilt, and twist as the stage moves along the axis. The stage moves in 6D space, therefore neglecting these additional error sources can result in a misrepresentation of actual stage repeatability performance.

Each linear (or angular) direction the stage moves (or rotates) in results in a positional error in that direction. That motion, which must not be neglected when nanometer-precision is desired, will have an associated repeatability of that error motion. Each point on a stage mounting surface will move in 3D space as of a result of this error motion in 6-DOF. It is the point repeatability of an infinite number of points attached to a stage that must be characterized by testing and specification data. Thus, each point repeatability will result in a spherical repeatability range.

Hennessey concludes, “ALIO applauds the new ASME standard officially published and made available a few days ago. In our view, this is a very important step towards True Nano® Positioning, allowing customers the ability to choose the best motion system for their applications based on a common standard rather than believing misleading, single dimensional specifications that vary from supplier to supplier. Because ALIO has already been applying these newly published measurement procedures for over a decade, our customers find themselves in the lucky position of not having to worry about the true performance of their products. ALIO will continue to be at the forefront of innovation and progress in the precision positioning industry. The new standard methods for the performance evaluation of single-axis positioning systems can only be the beginning though. Today’s motion systems are more complex, usually consisting of not just one linear axis, but combining multiple axis to 2, 3, 4 or 6 or more degrees of freedom. ALIO is ready to drive these next steps with the ASME and all other contributors to the ASME B5.64 to further improve the transparency and creditability of the precision motion world.”

(19th July 2023, Arvada, CO, USA) ALIO Industries (an Allied Motion Company) is at the forefront of innovation in ultra-precise and repeatable motion control systems, and as such is working to address the demands from manufacturers of increasingly complex and smaller and smaller integrated circuits (IC).

As complexity increases and size decreases, IC manufacturers lean more and more heavily on sophisticated metrology tools to validate the quality of finished products. Challenges especially escalate when looking at high volume manufacturing, where metrology tools are indispensable for ensuring quality control, optimizing processes, improving yield rates, enabling real-time monitoring, and keeping pace with technological advancements. They provide comprehensive inspection, precise measurements, and feedback on critical parameters, enabling manufacturers to detect defects, optimize processes, and maintain consistent quality throughout large-scale production. By investing in advanced metrology tools driven by best-in-class motion systems, manufacturers can maximize yield, reduce scrap rates, and proactively address deviations, ultimately ensuring the delivery of high-quality ICs in a competitive market driven by ever-advancing technology.

Bill Hennessey, President of ALIO Industries says, “Manufacturers of production and metrology equipment for small and complex ICs have unique and demanding requirements for ultra-precise motion control. They need motion control systems that offer sub-micron accuracy for precise positioning of tiny components, ensuring proper alignment and connection. High-speed operations are also crucial for efficient production throughput. Multi-axis control is necessary to enable synchronized movements in X, Y, Z, and rotation for accurate placement. These motion control systems must have a compact footprint, be flexible to adapt to different layouts, and provide long-term stability and reliability. Integration with automation is vital to streamline processes and maximize productivity. By meeting these demands, manufacturers can achieve high-quality IC production with improved yields and performance.”

In the fast-paced world of semiconductor manufacturing, metrology tools are part of the secret sauce that ensures perfection, and as such need to be controlled by bleeding edge motion control systems. They measure and inspect critical dimensions, overlay accuracy, and defects in integrated circuits, leaving no room for errors.

Hennessey continues, “With real-time feedback and control, these sophisticated tools empower manufacturers to make precise adjustments on the fly, boosting yields and slashing defects. It’s a game-changer for precision-driven production, where every measurement counts and perfection is the ultimate prize.”

ALIO Industries excels in creating motion control solutions for demanding metrology applications for a number of reasons. Firstly, ALIO’s expertise lies in delivering sub-micron accuracy and precise positioning required for measuring critical dimensions and overlay accuracy in ICs. Secondly, the company’s motion control systems offer multi-axis control and compact designs, catering to the intricate movements and space limitations of complex metrology systems.

Additionally, ALIO’s solutions provide the necessary stability, reliability, and adaptability to optimize processes, improve yields, and seamlessly integrate with automation in high-volume manufacturing environments. The company’s commitment to innovation and its deep understanding of the specific demands of metrology make them a trusted partner in delivering exceptional motion control solutions for these exacting applications, and it has the ability to customize solutions where required.

Hennessey concludes, “One notable example entailed the development of a semiconductor metrology low-profile XY-theta stage featuring a large open aperture. The design challenge involved an open frame stage with a configuration that hindered the implementation of a centered drive mechanism, thereby impeding the attainment of a symmetrical force distribution along the axis. ALIO successfully addressed this issue by creating a 300mm open center XY Nano Metrology stage. This stage exhibits a remarkable performance, characterized by a 3-Sigma, 6-D assessment encompassing parameters such as linear, straightness, flatness, pitch, yaw, and roll. Furthermore, the stage showcases a bi-directional repeatability within the range of less than +/- 250nm.”

ALIO’s team of dedicated engineers remains on hand to discuss your requirements when optimizing in the semiconductor industry.

(25th July 2023, Arvada, CO, USA) Precision motion control systems play a vital role in ensuring high quality and consistency in micro-electronic assembly and testing, particularly when it comes to accurate and repeatable positioning of test probes. ALIO Industries (an Allied Motion Company) is at the forefront of innovation in this area, and is able to provide motion systems that meet the incredibly exacting requirements that are common-place in such applications.

In micro-electronic assembly, the components are incredibly small and delicate, requiring precise placement and alignment. Precision motion control systems, equipped with advanced servo motors and encoders, enable micro-electronic manufacturers to position test probes with micron-level accuracy, reducing the risk of misalignment and potential damage to the sensitive components. This accuracy is critical for verifying the functionality of each individual component and ensuring that they work flawlessly within the intricate circuitry of electronic devices.

In addition, micro-electronic testing demands a high degree of consistency to detect even the slightest defects or variations in performance. Precision motion control systems allow for repeatable positioning of test probes during testing processes, ensuring that each component is examined under identical conditions.

By minimizing positional errors, these systems enable reliable and consistent data collection, reducing the likelihood of false positives or negatives in the testing results. This level of consistency is essential in producing reliable electronic devices, as any deviation or inconsistency in testing could lead to faulty products and costly recalls.

Bill Hennessey, President of ALIO Industries says, “The scale of the components being manipulated when testing and assembling micro electronic devices is regularly on the order of micrometers requiring reliable positioning in the low two-digit nanometers. At such small scales, even the slightest inaccuracies in positioning can lead to faulty connections, misaligned components, or inaccurate test results. At ALIO, we innovate high precision nanometer-level motion solutions that can overcome the challenges of testing and assembling micro-electronic devices by employing advanced technologies and design principles. Our solutions incorporate the most accurate linear motors on the market and high-resolution encoders to achieve nanometer-level positioning accuracy. Ironless linear motors offer precise and fast motion with outstanding responsive control at high bandwidths, ensuring that even the tiniest adjustments are made accurately. High-resolution encoders provide real-time feedback, allowing for closed-loop control and immediate correction of any positioning deviations.”

ALIO’s solutions also integrate sophisticated control algorithms and error compensation techniques to enhance accuracy further. Advanced control algorithms optimize motion trajectories, ensuring smooth and accurate movements. Error compensation techniques identify and correct systematic errors, such as thermal effects or nonlinearities, which can adversely affect positioning accuracy. By combining these technologies, ALIO’s high precision nanometer-level motion solutions can reliably and consistently address the challenges posed by microelectronic assembly and testing at such minuscule scales.

Hennessey continues, “ALIO’s rotary and linear motion systems provide high precision down to the nanometer level; excellent bi-directional repeatability, high levels of precision and accuracy, even after thousands or millions of cycles; fast response time, quickly responding to changes in position requirements, allowing for efficient and rapid testing and assembly processes; and minimal backlash ensuring that positioning remains accurate and consistent, even when changes in direction are required. As such, our precision motion control systems are indispensable tools in micro-electronic assembly and testing, guaranteeing the utmost accuracy and repeatability in positioning test probes and contributing to the overall quality and reliability of electronic products.

ALIO’s team of experts can be contacted today to discuss your specific testing and assembly requirements.