Custom Stages

The required travel range is one of the most critical factors to consider when designing a custom stage. The travel range is the distance that the stage needs to move to complete its intended function. The travel range impacts the size, weight, and complexity of the stage. For example, a stage with a shorter travel range will be smaller and lighter than a stage with a more extended travel range. Alternatively, a longer travel range may require additional components, such as extended rails or a more complex drive mechanism, to support the longer travel distance. The travel range will also impact the accuracy and repeatability of the stage. Unfortunately, longer travel distances can be more challenging to achieve with precision.

Therefore, when designing a custom stage, it is vital to carefully consider the required travel range to ensure that the stage meets your application's accuracy, repeatability, and functionality requirements.

The accuracy of a stage refers to how closely it can achieve its intended position compared to the desired position and depends on the following factors:

• the precision of the components used
• the control system
• the environmental conditions in which the stage will operate

The accuracy requirements of a custom stage are generally determined by the application's specific needs, with some applications requiring sub-micron accuracy. Higher accuracy requirements may demand the use of more precise components or more stringent manufacturing processes to achieve the desired level of accuracy. Additionally, the control system must be designed to provide the necessary feedback and control to achieve the required accuracy. If the required level of accuracy is not achieved, it could lead to system failure, reduced performance, or increased downtime.

Load capacity refers to the maximum weight the stage can carry while maintaining accuracy, repeatability, and functionality. The load capacity of a stage is determined by the size and strength of the stage's components, such as the rails, bearings, and drive mechanism.

To ensure that a custom stage can support that load while maintaining the necessary accuracy and repeatability, it is crucial to consider the minimum and maximum load capacity requirements during the design process. Additionally, the stage's load capacity can impact its size, weight, and complexity, just like the required travel range. A stage with a higher load capacity may require larger or stronger components, which can increase the stage's size and weight.

As a result, when designing a custom stage, it is essential to carefully balance the load capacity requirements with the other design considerations to ensure that the stage meets the application's needs while remaining practical and feasible to manufacture and operate.

The operating environment refers to the conditions in which the stage will operate, such as temperature, humidity, vibration, and air quality. The operating environment can impact the performance, accuracy, and lifespan of the custom stage.

For example, suppose the custom stage operates in a high-temperature environment. In that case, the materials and lubrication used in the components of the stage must be carefully selected to ensure that they can withstand the heat without degrading or failing. Similarly, if the stage operates in a high-vibration environment, the stage's components must be designed to withstand the vibrations without affecting the stage's accuracy or repeatability. The operating environment can also impact the required level of protection for the custom stage. If the stage operates in a cleanroom environment, the components must be designed to prevent the release of particles or contaminants that could compromise the cleanliness of the room.

Therefore, when designing a custom stage, it is crucial to consider the operating environment carefully. The design must take into account the environmental conditions that the stage will be exposed to and ensure that the stage's components, materials, and protection measures are appropriate for those conditions. Failure to consider the operating environment could result in reduced performance, decreased accuracy, and increased maintenance requirements.

In a custom stage, system integration refers to the integration with other components and subsystems, such as motion controllers, sensors, and software. When designing a custom stage, it must integrate seamlessly with the other components and subsystems to ensure the overall system functions correctly. This can include designing the stage's control system to communicate with the motion controller or sensors, ensuring that the stage's software is compatible with the system's software, and designing the stage's mechanical interface to fit with the other components in the system.

The system integration requirements can impact the design and manufacturing processes used to create the custom stage. For example, if the custom stage requires compatibility with a specific motion controller or software system, the design must incorporate those requirements from the outset to ensure that the stage can integrate correctly.