Elif Γzaksu
Corporate
- Thread Author
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Are you ready to discover synchronized motion control and galvo scanning architectures designed to eliminate stitching errors in large-area precision manufacturing and micro-display assembly? Aerotech is introducing groundbreaking innovations in this field!
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π¬ A New Era in Micro-Manufacturing
Aerotech is showcasing advanced laser scanning algorithms and multi-axis motion control platforms developed for micro-manufacturing sectors. These synchronized positioning systems integrate galvo scanners with servo stages to support high-precision applications, including the production of micro-sensors and organic light-emitting diode (OLED) displays.
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βοΈ Synchronization of Servo Axes and Optical Scanners
A fundamental limitation in traditional laser micro-machining is the physical boundary of the scanner's field of view. To process surfaces larger than this optical limit, systems typically employ a step-and-scan methodology. However, this method can lead to overlapping stitching errors and thermal stress misalignments at the joining edges.
The Infinite Field of View (IFOV) mechanism solves this problem by continuously synchronizing linear or rotary mechanical servo axes with optical laser scanners. By coordinating the high dynamic positioning of a galvo scanner with the wide range of motion of a mechanical servo stage, the system can process large areas without stopping for repositioning. This eliminates stitching errors and increases overall efficiency.
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π‘ Eliminating Stitching Errors in Micro-Display Manufacturing
The continuous processing capability provided by synchronized motion control ecosystems is critical, especially for the production of micro-actuators, micro-sensors, and OLED displays. In addition to expanding the field of view, control approaches for flexible 5-axis laser micro-machining are implemented using the AGV5D galvo scanner. This hardware combination allows for precise positioning in the nanometer range, which is critical for high-density electronic assemblies.
Aerotech European Director Simon Smith states that multi-scanner systems equipped with IFOV controllers facilitate complex, large-area, and high-dynamic laser processing across multiple axes without the traditional stitching constraints.
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π οΈ Driver Integration and Process Validation Capabilities
Operating continuous, high-dynamic multi-axis systems requires robust software and hardware integration. The Automation1 motion control platform provides the core infrastructure for these synchronized movements. Recent updates to the platform allow for direct integration of XA4 pulse width modulation (PWM) drives. These compact single and multi-axis servo motor drives are designed for dense control cabinet installations, reducing hardware complexity while expanding the platform's programming capabilities.
To support the deployment of these advanced laser micro-machining systems, a dedicated laser laboratory in FΓΌrth, Germany, became operational at the beginning of 2026. This facility serves as a central European hub for testing and validating laser-based manufacturing processes, as well as for assembling precision drive components.
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π Competitive Comparison and Technical Details
In the market for precision motion control and advanced laser micro-machining, the synchronization of galvo scanners with mechanical stages is a primary benchmark for continuous path processing. Infinite Field of View technology directly competes with synchronized architectures such as the XL SCAN system, jointly developed by ACS Motion Control and Scanlab. Both technologies aim to eliminate the efficiency bottlenecks and stitching inaccuracies inherent in traditional step-and-scan equipment.
When evaluating these continuous scanning platforms, engineers compare criteria such as dynamic tracking error, tracking lag, and absolute spatial accuracy. Traditional step-and-scan systems require the mechanical stage to come to a complete stop before the laser fires, which causes mechanical resonance and limits production throughput. In contrast, synchronized systems maintain a constant mechanical stage velocity while optical galvo mirrors dynamically compensate for the stage's position in real-time. High-level motion control platforms managing these operations achieve tracking lags in the sub-microsecond range and absolute spatial tracking accuracy of less than one micrometer, depending on linear encoder resolution and closed-loop servo update rates.
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Aerotech's Infinite Field of View technology opens new horizons in industrial manufacturing by increasing efficiency and precision in laser micro-machining. This innovative approach promises faster and error-free production processes, especially by overcoming the challenges encountered in micro-display and sensor manufacturing.
