Industry 4.0 showcased at Southeast Asia’s biggest event for the metalworking, machine tools, and automation industries opened with a prestigious ceremony graced by YBhg. Datuk Hanafi Sakri, Deputy Secretary General (Industry) of the Ministry of International Trade and Industry (MITI). YBhg. Tan Sri Dato Sri Dr Hj Mohd Nasir Bin Mohd Ashraf, Organising Chairman, Informa Markets Malaysia, YBhg. Dato Dr Tan Chin Huat, Chairman of METALTECH & AUTOMEX, and Gerard Leeuwenburgh, Country General Manager of Informa Markets Malaysia, were also present. The ceremony highlighted the significance of METALTECH & AUTOMEX 2024 as a platform for growth and innovation in Malaysia’s manufacturing sector.

Datuk Hanafi delivered a keynote address about Malaysia’s manufacturing sector.

“We are witnessing impressive growth, with investments surging to RM152 billion, a remarkable 80.3% increase compared to the previous year,” he declared. He continued by emphasising the importance of METALTECH & AUTOMEX, saying, “These exhibitions play a crucial role in propelling Malaysia towards becoming a regional leader in smart manufacturing, advanced technologies, and high-tech industries.”

METALTECH & AUTOMEX 2024 boasts an unparalleled showcase, featuring over 1,500 brands and companies from 40 countries. With 18,000 trade buyers and visitors anticipated from 49 countries, the event is poised to be a dynamic hub for forging new partnerships and exploring the future of manufacturing.

Themed “Industry 4.0 Innovations: Powering Malaysia’s Manufacturing Future,” the event places a strong emphasis on the transformative potential of Industry 4.0. Visitors can delve into dedicated pavilions from industry leaders in Germany, South Korea, mainland China, Singapore, and Taiwan region, all showcasing groundbreaking solutions in automation, robotics, and digital manufacturing.

“This year’s METALTECH & AUTOMEX goes beyond just speed,” said Mr. Gerard Leeuwenburgh, Country General Manager of Informa Markets in Malaysia. “The theme highlights how Industry 4.0 advancements can optimise processes, drive efficiency, reduce costs, and promote sustainability. Businesses can discover eco-friendly technologies that minimise environmental impact, achieving a future where efficiency and sustainability go hand-in-hand.”

The manufacturing landscape is undergoing a revolution. AI, robotics, and the IoT are fundamentally reshaping how products are designed, produced, and delivered. METALTECH & AUTOMEX 2024 empowers businesses to stay ahead of the curve by providing a platform to explore these trends, connect with solutions providers, and gain valuable insights from industry experts.

“METALTECH & AUTOMEX 2024 isn’t just an exhibition; it’s a game-changer for Malaysian manufacturers. By showcasing the latest Industry 4.0 advancements – from automation to AI-powered solutions – the event serves as a vital launchpad for progress. These innovations hold the key to greater efficiency, enhanced sustainability, and a stronger position in the global marketplace,” emphasised Dato Dr Tan Chin Huat, Chairman of METALTECH & AUTOMEX.

In addition to the exhibition, METALTECH & AUTOMEX 2024 featured a comprehensive program of industry-leading seminars, offering valuable insights and knowledge-sharing opportunities for manufacturers and professionals navigating the evolving industrial landscape.

Following the opening ceremony, Guest of Honour, YBhg. Datuk Hanafi Sakri, along with Chairman Dato Dr Tan Chin Huat and Country General Manager Gerard Leeuwenburgh, embarked on a tour of the exhibition floor. This high-profile visit presents a golden opportunity for exhibitors. It allows them to directly showcase their cutting-edge technologies and solutions to key decision-makers, potentially leading to valuable partnerships and business deals.

METALTECH & AUTOMEX 2024 is a global stage for industry giants to showcase their latest cutting-edge technologies for the first time. From pioneering advancements in automation and robotics to revolutionary solutions in digital manufacturing, this event offers a glimpse into the future of the industry.

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Elevating Virtual Realities

Zygo prides itself in ensuring Virtual reality (VR) creates a fully immersive experience that allows users to feel like they are actually in the virtual world. This is done by using headsets that block out the user’s real-world surroundings and display a computer-generated world in their field of view.

Zygo’s client with operations in the United States, Europe, China, and Japan develops innovative (VR) solutions that enable users to experience the best in VR and immersive reality technologies. As the company develops new products on its optics, metrology was extremely important to Captain Lin, a former director at the company.

Metrology tools for immersive reality devices quantify surface form, diffraction angles and efficiency, assembly tolerances, and surface roughness, and assist in development and prototyping, performance evaluation, and production quality control.

“Creating VR products utilising headset lenses and cellphone screens requires extreme precision. That’s why we need the best metrology equipment available,” said Captain Lin. “My skill is in using metrology equipment that can perform complex calculations to help manufacturers adjust their mold base or their compensation for lens deviation so that we get optimum results. When I use Zygo’s equipment and software, everybody trusts the results. That’s why I love using Zygo to analyse things,” he added. To ensure that it was using the best equipment for the task, the company turned to Zygo, the leading optical metrology innovator.

Optimising VR Precision

Zygo recommended that the VR solutions company use its DynaFiz® Laser Interferometer. Purpose-built for reliable interferometry in vibration-prone environments, this equipment is versatile and flexible enough to address a wide range of application needs, from high-end telescope testing to live phase feedback for active alignment of optical systems. Its fully coherent optical design enables highest light efficiency, improving dynamic performance

Read more here at page 44

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Optical engineers prefer to evaluate the mechanical engineer’s design by moving it into their optical design codes. This involves moving the mechanical engineer’s CAD model into a structural analysis finite element code, subsequently moving the finite element results into an optical design code.

The optical engineers have developed interpreters and interpolators that facilitate their activity. This allows the optical engineer to observe the mechanical design’s influences on the optical image. The optical codes are generally large-displacement nonlinear solvers for the optical geometry. This process has two drawbacks for the mechanical engineer.

First, it requires a fairly complete CAD model of the system which only occurs relatively late in the mechanical engineering activity. Consequently, mechanical design deficiencies are uncovered late in the mechanical design process. Second, it is problematic to trace the optical effects back through the interpreters and interpolators to the mechanical design features that may be causing the optical problems. Therefore, mechanical design changes become difficult to formulate, rationalise and justify.

The optical engineers assume their large displacement non-linear codes are required to analyse the perturbations caused by mechanical deflections. However, permitted deflections of the optical elements are usually quite small, on the order of microns for structures of meter-sized dimensions.

For perturbations of this magnitude it may be shown that a non-linear solver is not required for engineering accuracies. In fact, it can be argued that the optical functions are more linear than the solid mechanics functions, of which the finite element method itself is but a linear simplification.

Read more here

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Onto Innovation Inc. launched of the Firefly G3 inspection and metrology system for automated process control during high volume production of panel-level substrates. The Firefly G3 system was shipped to a tier one customer supporting a variety of AI chiplet based panel-level packages with several additional customers expected to take delivery in the first half of 2024.

The Firefly G3 system’s inspection and metrology capabilities uniquely complement Onto’s JetStep^® family of panel-level lithography systems, using proprietary feed-forward and feedback software, providing high-resolution data to optimise layer-over-layer overlay accuracy throughout all layers on each side of the panel being processed, a unique capability in improving current panel performance and yield.

*According to TechInsights, demand for high performance compute servers supporting applications in AI, and the continued evolution of GPU technologies for gaming and automotive, has contributed to the overall growth for panel-level technologies swelling to over 25% CAGR through 2028.

“The Firefly G3 system, when combined with Onto’s Clearfind^® technology and TrueADC^® software, replaces multiple tools and operators used for defect review and classification, which enables customers to improve yields and increase their panel substrate throughput,” says Mayson Brooks, vice president and general manager of Onto’s inspection business.

“Manufacturers using manual inspection methods for defect review utilize multiple human inspectors to identify and reject critical defects while categorizing minor and negligible defects that are subject to human error.”

“The flexibility of the Firefly G3 system is further demonstrated by uniquely serving a wide range of applications, such as the detection of under-film bubbles and particles. If these defects are not found at an early stage, they lead to shorts and opens later in the manufacturing process,” adds Brooks.

This next-generation Firefly system goes beyond 2D inspection and metrology by supporting additional process control steps through the introduction of 3D metrology sensors. With the new-generation 3D sensors, the system can measure film thicknesses and the height of metal RDL lines. The addition of these sensors allows customers to collect critical data required to mature their process in a shorter amount of time.

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Hexagon’s laser tracker team were contacted during 2022 by a major aerospace customer interested in changing their current measurement process (which involved a tracker and reflector measurement process) to direct scanning with the ATS600. Their current process involved an operator being given a list of surface points on the part, and then bringing a reflector to each of these locations to take a measurement.

Points were only recorded once the reflector reached the coordinate. Due to the size of the part, a scaffold and safety equipment is required, which needed to be repositioned multiple times due to the typical size of the parts being measured. This was an extremely time-consuming process, which was the key motivator for investigating the switch to direct scanning.

The company was concerned if the performance of the ATS600’s direct scanning would reach their tolerance requirements – Hexagon have been open about the convenience of direct scanning coming at the cost of reduced accuracy when compared to reflector inspection. A round of testing was planned with the business’ local Hexagon team and a demonstration unit, with the goal of showing whether or not the reflectorless measurement results would be good enough to meet their tight aerospace tolerances.

Read more here https://shorturl.at/npGTV

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In addition to tactile measurement in the grinding and eroding machines, WALTER (a member of United Grinding) now offers a new and innovative non-contact option: Laser Contour Check. The new blue laser, in combination with the intelligent measuring system for high-precision measurement of various tool parameters on cylindrical tools with diameters from 1 to 52 mm, avoids possible damage to cutting edges or measuring errors that can occur due to wear on the probe tip during tactile measurements.

Measurements are made directly in the analogue laser beam on the entire tool contour and not only at specific points as with the tactile or digital measuring method. Deviations can thus be compensated directly in the process.

A short measuring time including cleaning of approximately 16 seconds (depending on the tool type) for diameter measurement ensures increased productivity. Optimised programme sequences for cleaning and compensation can be programmed and adapted by the operator.

The measuring system is integrated directly into the working area of the machine and moves into position when required. The blue laser beam used offers improved accuracy compared to the conventional red laser, as blue lasers have a shorter wavelength, thus reducing diffraction effects and optimising the laser beam geometry.

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The Metrology lab is a milestone event, graced by Peter Johnson, Vice President and General Manager of Fabrication for Boeing Commercial Airplanes, represents a significant leap forward in the company’s commitment to customer-centric investments and enhanced value delivery. The facility also underscores Rossell Techsys’ unwavering dedication to quality and customer satisfaction.

“We are delighted to inaugurate our state-of-the-art Calibration and Metrology Lab,” said Mr. Rishab Mohan Gupta, Promoter Group member and Director, Rossell India Limited. “This metrology facility represents our commitment to maintaining the highest standards of precision and quality in all aspects of our operations. It allows us to deliver exceptional value to our customers, who rely on us for critical components. With this investment, we enhance our capabilities and reinforce our position as a trusted leader in the aerospace and defense industry.”

“We congratulate Rossell Techsys for investing in this Calibration and Metrology Lab and look forward to our continued partnership,” said Salil Gupte, President, Boeing India. “It reflects Rossell Techsys’ commitment to providing global quality products and services to their customers. This is also another example of Boeing’s commitment to grow world-class precision manufacturing capabilities along with its local partners in India, for India, and the world.”

The lab, equipped with the very latest in technology, is slated for ISO17025 certification. Integrated into Rossell Techsys’ operations, it ensures meticulous control over the Metrology process, ensuring accuracy and reliability across products.

The company produces 3000+ unique parts, of which 2000+ unique parts are for Boeing alone. It uses extensive tools that require periodic calibration and metrology testing.

The in-house facility, in proximity to the shop floors reduces tool calibration time, maximizing efficiency. Rossell Techsys remains an innovative leader, providing comprehensive engineering solutions for aerospace and defense industry and the Calibration and Metrology Lab showcases its dedication to excellence and focus on exceeding customer expectations.

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From Users For Users

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The AUDIRA system provides highly accurate and reproducible nanometer-level measurements of buried features and defects, such as voids, in advanced memory and logic devices.

“AUDIRA is a game-changer for advanced semiconductor manufacturing. It provides measurement data that was previously not available without having to remove the wafer from the line,” said Hamed Sadeghian, CEO, Nearfield Instruments.

“Most importantly, the AUDIRA gives process engineers insight into the wafer’s innermost layers – details they never were able to carry out measurement before nondestructively and sometimes would never have even known to look for. AUDIRA, like our first product QUADRA, turns in-line metrology and inspection into an added value in the semiconductor manufacturing process.”

Nearfield Instruments anticipates that AUDIRA will complement transmission electron microscopy (TEM) and critical dimension-scanning electron microscopy (CD-SEM) for subsurface process control measurement. AUDIRA uses an acoustic approach that is fast, very precise and non-destructive with the added advantages of being in-line with a fast turn-around time.

With AUDIRA, Nearfield Instruments combines an acoustic microscopy technique with its own proprietary atomic force microscopy (AFM) technology. The AFM probe is used to ‘listen’ to the sound waves coming through the wafer layers.

The wave interacts with all the transitions and surfaces within the device and reflects information back. The pattern of that reflected wave and the time of arrival contains data about the structure below the surface.

The AUDIRA scans across the die, with each step as small as several tenths of a nanometer. The data is then translated into a comprehensive pattern of the underlying layers that provides measurement of subsurface features.

AUDIRA is also valuable for measuring shallow features through the surface. Using the AFM probe, surface elasticity variations can be quickly measured to reveal details about the structure below.

Nearfield Instruments works with customers to develop a recipe for when to use acoustics and at what frequency, for which layers local elasticity measurements are best, and when to switch to wave propagation schemes. Its product portfolio also includes the QUADRA surface metrology solution.

They feature a groundbreaking multi-miniaturized AFM head architecture combined with feedforward trajectory planner (FFTP) imaging technology to enable on-device, non-destructive measurements for in-line process monitoring of very high-aspect ratio structures as well as hybrid bonding and EUV resist critical dimension metrology.

QUADRA has shown a factor of more than 100x improvement in imaging acquisition time when benchmarked against existing state-of-the-art AFM systems. AUDIRA is available now and the first systems will ship in Q2 2024 to top semiconductor fabs worldwide.

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Hexagon’s Manufacturing Intelligence division released a new modular 3D laser scanner designed for large surface inspection, for use with both its laser tracker and portable measuring arm devices. The new Absolute Scanner AS1-XL is built on the same SHINE technology as its flagship Absolute Scanner AS1, allowing it to collect extremely clean 3D data at very high speeds from even the most challenging surface types.

With a wider scan line, the new scanner is designed for inspecting large surfaces and deep cavities across inspection applications such as aerospace panels, marine propellers and large automotive castings. The AS1-XL boasts an ultra-wide scan line of 600mm at mid-range.

Together with its 1.2 million points per second point acquisition rate and 300 Hertz frame rate, this makes it ideal for scanning large surfaces quickly without losing inspection detail. The scanner also features an extended measurement stand-off distance of 700 millimetres, which paired with its 600 millimetre working range allows for hidden point measurement capability of up to a metre.

“Since even before the launch of the AS1 we’ve wanted to deliver that same level of data collection quality and automation readiness in a device focused on large surface inspection,” says Daniel Moser, Laser Tracker Product Director at Hexagon. “We’ve seen with our previous generation of scanners that the appetite and applications for a dedicated large-scale scanning device are out there in the market. With the AS1-XL, we’ve been able to deliver on the promise of that large surface measurement concept in a far more satisfying way thanks to our new scanning technology that is ten times faster than our previous generation, the LAS-XL.”

The proprietary intelligent exposure algorithms that make up Hexagon’s SHINE technology are key to the performance of the AS1-XL, allowing it to digitise almost any material, including multiple surface types and colour finishes, within a single scan pass with no need for settings adjustment. It is this and the scanner’s automation compatibility that set it apart from the previous generation LAS-XL, a handheld-only device.

The high measurement speed and large stand-off distance of the AS1-XL make it ideal for a wide range of automatable inspection tasks – the former allowing the scanner to keep up with modern robot technology rather than being a bottleneck to robot path speed, and the latter minimising risk of collision by not requiring the robot path to pass so close to the inspection object.

As with the Absolute Scanner AS1, the AS1-XL has been designed with a modular concept that allows for compatibility with both Hexagon’s flagship laser tracker and portable measuring arm systems – the Leica Absolute Tracker AT960 and Absolute Arm 7-Axis respectively. The quick-mount design and minimal warm-up period make the AS1 and AS1-XL a hot-swappable combination, allowing users to move quickly back and forth between high-density detailed scanning and larger surface inspection using either a portable arm or laser tracker at a moment’s notice.

“The Absolute Scanner AS1 has really been embraced by the market since its launch in 2021, and it’s great to be completing the 3D scanning toolkit of our portable measuring arm line-up with an equally impressive device in the AS1-XL,” says Anthony Vianna, Portable Measuring Arm Product Director at Hexagon.

“Our Absolute Arm range offers a market-leading measurement volume of up to 4.5 metres in diameter, making it an ideal platform for a large-scale device like the AS1-XL. And even with our smaller diameter models, the hidden area coverage provided by that extended stand-off distance opens up a lot of applications that have previously been hard to cover, such as automotive, rail and aerospace interiors.”

As with the AS1 and latest iteration of the Absolute Arm range, the AS1-XL is IP54-rated, allowing for safe and reliable operation in the challenging shop floor environment into which quality inspection is increasingly being taken. The AS1-XL is available now from local Hexagon representatives, and more information is available on the Absolute Scanner section of the Hexagon website.

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Yusin Hu, Taipei, DIGITIMES

Saccade Vision creates a feature-based 3D scanning technology, similar to the lidar sensors used by carmakers, for the inspection and measurement sector to improve quality control and yields.

Well aware of where improvements are needed in the inspection and measurement industry, the founders of Saccade Vision developed feature-based 3D scanning technology to reduce time, costs, and defect rates for manufacturers of industrial products.

The Israel-based startup was founded by three veterans in the inspection industry: Alex Shulman, Evgeni Levin, and Ran Sagi. Saccade means rapid eye movement. The scanning technology, like those adopted by automakers, is designed to simulate human vision. Saccade Vision’s system uses a micro-electromechanical system (MEMS) laser illumination module as a light source that is able to scan from multiple directions.

Shulman stressed that “feature-based scanning” means the system can focus on certain parts of the object and obtain higher precision.

Less costs and higher yields

Quality inspection requires line workers to conduct repetitive work, day in, day out. Humans get tired of doing the job that requires precision; machines don’t. In a way, robots can improve human lives by taking over boring jobs.

However, the reason why inspection has yet to become fully automated is that in many cases, the costs for application-specific automation are too high for companies to even consider. As the lifecycle of electronics shortens, it is simply not viable for manufacturers to invest in application-specific automation.

Developing application-specific inspection automation incurs high costs, and “these costs could reach five to 10 times higher than the costs of hardware and software inspection components,” said Shulman.

Client feedbacks showed that Saccade Vision’s feature-based scanning technology can reduce the overall costs for automation by 2-3 times. It reduces the hidden labour costs behind manual inspection while making the inspection robust and reliable. Moreover, “automation just increases yield rates, undoubtedly,” he added.

Saccade Vision’s solution can be applied to various applications. In the future, they hope to reach full automation. Although for some high-quality, high-precision products, it may still require qualified operators to monitor the process. In most cases, the computer will automatically gather the product manufacturing information (PMI) from CAD (computer-aided design) models.

Integrated solution demo
Image Credit: Saccade Vision

Use case

Saccade Vision’s largest use case is dimensional inspection, namely measurement of metal parts, post-CNC products, sheet-bending, stamping, plastic injection molding in sectors that require high-precision manufacturing and tight quality control – including EMS electronics manufacturing, automotive, aerospace, military, and others.

One of its clients is an S&P 500 electronics manufacturer, which has used Saccade Vision’s technology to inspect so far over one million units and discovered some defects that the manufacturer was not even aware of.

Shulman said they are now working with equipment manufacturers, too, to integrate their 3D scanning technology and robotic automation – such as large Germany-based robotics solution provider and Italy-based Euclid Labs. The latter has integrated its feature-based scanning to assist metal-working suppliers.

In addition to industrial applications, Shulman added that future potential use cases range from medical imaging to logistics and other robot-related applications.

Supply chain

Such high-precision technology for sure requires very specific camera sensors. Amidst the semiconductor shortages, Saccade Vision needed more flexibility to manage its product design and supply sources. Shulman pointed out that they are now actively looking for suppliers worldwide for FPGA cameras.

Saccade Vision now has sufficient inventories to supply to manufacturers worldwide. With the pandemic hopefully behind us right now, the company now looks to expand from Israel, Europe to Asia and the US.

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The post Saccade Vision Uses Mems-Based Cameras To Improve Measuring And Quality Control appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.