Custom automation platform replacing highly skilled manual assembly processes for precision micrometer component manufacturing
A leading manufacturer of precision measurement tools relied on a highly skilled manual process to assemble critical micrometer stem, spindle, and binder nut components. The assembly process required multiple machining, cleaning, polishing, lapping, and threading operations, with product quality heavily dependent on operator experience and tactile feedback.
As experienced workers became increasingly difficult to recruit and retain, the manufacturer sought to reduce reliance on specialized labor while maintaining the precision and quality standards required for its micrometer product line. High employee turnover and a shrinking pool of skilled labor created long-term concerns regarding production sustainability and workforce availability.
The process also presented significant technical challenges for automation. Extremely fine threads required precise alignment to prevent cross-threading, while multiple product variations demanded a flexible manufacturing platform capable of accommodating different part geometries and assembly requirements.
The manufacturer partnered with Re:Build DAPR to develop a fully automated assembly system capable of replicating the precision of skilled operators while improving consistency, reducing labor dependency, and supporting future production growth.
Re:Build DAPR began by studying the existing manual assembly process and identifying the critical variables that influenced product quality. Extensive evaluation was performed on lubricants, lapping compounds, cleaning methods, robotic handling technologies, and precision motion control systems to determine how manual operations could be reliably automated.
A major focus of the project involved recreating the subtle thread alignment techniques previously performed by experienced operators. Because cross-threading could permanently damage parts, the team developed a strategy that combined precision motion control, force feedback, and custom software routines to ensure proper thread engagement before assembly.
The engineering team also evaluated multiple automation architectures, robotic configurations, and cleaning methods before selecting a fully automated solution capable of handling multiple product variants while maintaining process consistency. Safety, cleanliness, and long-term maintainability were incorporated throughout the system design.
Re:Build DAPR designed and built a fully automated micrometer assembly platform that performs precision machining, cleaning, polishing, threading, and assembly operations with minimal operator intervention.
Key system features included:
One of the most innovative aspects of the system was the thread alignment routine developed using SMAC actuators. By combining high-resolution encoder feedback with custom motion algorithms, the system automatically detects thread alignment prior to engagement, eliminating cross-threading while maintaining consistent assembly quality.
The machine was also designed to improve cleanliness and reliability through automated lubrication control, debris containment features, clean and dirty gripper strategies, and protective covers for precision components.
Re:Build DAPR successfully delivered an automated assembly system capable of producing approximately 52 assemblies in five hours while achieving acceptance rates of approximately 95 percent.
The system significantly reduced reliance on highly skilled manual labor while maintaining the precision required for micrometer assembly. Operators can now focus on higher-value manufacturing activities while the machine performs repetitive assembly tasks with consistent and repeatable results.
The platform also improved process visibility, troubleshooting capability, and product consistency by replacing subjective operator judgment with repeatable automated processes and recipe-driven controls.
The project established a flexible manufacturing platform capable of supporting multiple product variants while providing the customer with a scalable solution for future workforce and production challenges.
The micrometer assembly system includes:
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