Complete solutions for microdispensing
Transition from a manual process to an automated system solution for precision processes with high repeatability
When a manually executed process reaches its natural limits, room for innovation begins. In a recent customer project, a delicate assembly process from the medical technology sector was almost fully automated — and optimised far beyond its original scope.
The goal was to bond and cure small parts inside stainless steel tubes using UV adhesive with high precision. The result is a comprehensive microdispensing solution that offers far more than just simple glue application. It can also handle position detection, small part handling, surface treatment and process control, all of which are implemented based on the marc0 Gantry System with a range of specialised modules.
The manual process: precision under the microscope
Originally, the process was carried out entirely manually: tiny parts were positioned under a microscope by visual inspection and glued at specific points. Experienced specialists intuitively compensated for component tolerances – through routine, sensitivity and experience. It was precisely this manual flexibility that proved to be a particular challenge in the course of the project when the aim was to achieve a uniform, standardised process.
From manual handling to automation – step by step to a system solution for precision processes
Through our system development, the manual assembly process was not only automated but also extended with precise inspection steps. The aim was to replicate the capabilities of manual manufacturing — such as visual position detection — with maximum precision. At the same time, standardised inspections, automated workflows, and adaptive dispensing strategies were integrated into the system solution.
Process overview:
- Manual loading of parts into a clamping jig
- System checks and UV-LED functionality test
- Camera detection of XY positions using AI
- Height measurement (Z) via touch sensor
- Cleaning and dummy dispensing
- AI-supported recognition of other small parts in a tray (bulk)
- Pickup with vacuum gripper
- Plasma activation of the underside of the small part
- Microdispensing of UV adhesive into the target position of the part
- Placement and pressing of the component (vacuum + pusher)
- UV-LED curing
- Repetition of the process for all parts in the jig
The core: The marc0 Gantry System
The central mechanical base is the marc0 Gantry System — a modular, highly precise motion platform. All relevant process modules are mounted on or attached to this system. Its open architecture allows various components to be flexibly combined and controlled along defined axes. The marc0 thus provides the necessary basis for operations such as dispensing, positioning or placing components in conjunction with the connected modules. This ensures high repeatability and precision.
Module overview – a perfectly tuned system solution
Dispensing head with a high precision valve
The dispensing head enables non-contact application (jetting) of UV adhesive along predefined movements — e.g., in double-circle patterns. The piezo valve guarantees a constant, reproducible volume per cycle — a key element in microdispensing.
Two touch sensors – vacuum gripper & pusher
Both modules are based on a sensitive spring parallelogram design for force measurement.
- Vacuum gripper: detects the contact point, lifts the small part precisely and positions it.
- Pusher: presses the part into the adhesive bed in a precisely controlled manner — ensuring that it does not come into contact with the UV adhesive.
Plasma module for surface activation
A directed plasma jet activates the underside of the small part before bonding to improve wettability by the UV adhesive. The movement is performed in a star-shaped, precise and uniform pattern to ensure consistent surface activation.
Camera with AI-based image processing
The integrated camera captures the exact position of the components as well as the locations of the small parts to be picked up — even in case of challenging geometries or reflective surfaces. An internally trained AI guarantees reliable detection and enables flexible process control.
Chassis and enclosure
The system is fully housed within a lightproof enclosure. This protects the system against process disruptions from environmental influences and reliably shields operators – especially during UV curing – from radiation exposure.
Intelligent control: flexible Python scripts with scope for customisation
At marco, a complete solution for microdispensing also includes the appropriate software. All processes are programmed inhouse using Python. The modules communicate via interfaces such as RS232 or Ethernet. The HMI offers intuitive popups for manual intervention, adjustments and authorisations.
Thanks to the highly customisable nature of the software, adjustments can usually be made even after the project has been completed, depending on the scope and depth of the desired changes.
Process reliability via calibration and smart inspections
Before production begins, the system automatically tests all UV-LEDs using a sensor and documents the results for each individual position. The camera position is verified via a dummy dispensing run and tools such as the gripper and pusher are calibrated using a casting compound. The operator can correct any detected deviations via the HMI. This ensures that all components in the system work together in perfect harmony.
More than just automation – process awareness included
A special added value is that, in close collaboration with the customer, originally planned process steps, such as inserting the small part under pressure, can be optimised and, in some cases, even eliminated. Such insights only arise when an automation partner not only delivers technology, but also thinks through, supports and actively participates in the entire process.
A complete solution instead of compromise
This system solution is distinguished not by a single module or specific technology, but by the precise interplay of all components, which are tailored to the individual process. Many modules originate from the marco portfolio, while others have been further developed or newly engineered. The result is not an off-the-shelf product, but rather a comprehensive microdispensing solution born from iterative development, close collaboration with customers, and an in-depth understanding of processes.
Transferability to other industries and applications
The resulting system solution can be applied to a wide variety of industries. This modular concept demonstrates its strengths wherever small parts need to be positioned, dispensed or bonded with precision.
It showcases the team's ability to develop customer-specific solutions in areas such as research and development, design as well as hardware and software engineering to develop customer-specific solutions regardless of application or industry.
Contact us – for your individual complete solution
Are you facing a similar process, or one that is completely new? We design system solutions for precision processes that adapt to your needs, rather than the other way around. Talk to us — we look forward to taking on your challenge!
Get in touch with us. We will support you on your way to process reliability.