Introduction: Meeting modern automation demands
The 2024 World Robotics Report stated that approximately 4.3 million robots are operating globally. From large industrial robots and single-station collaborative robots to SCARA robots and 6-axis robots, robotics and automation continue to drive innovation. In some industries, however, such as medical devices, photonics and semiconductors, the precision required has not been possible with large robot arms. Microautomation is growing rapidly as industries require smaller, more precise, and more flexible solutions. This blog explores how compact robots—like those from Mecademic—address common integration challenges and create new opportunities.
Why microautomation matters for integrators
In industries such as electronics, optics and photonics, medical devices, or quantum sensors, precision is measured in micromillimeters and micrometers (µm). Traditional robot arms are too large to operate with the precision required. Manual operations are time-consuming and can increase cycle times and reduce output, making scaling for large projects a challenge.
One of the challenges with traditional robotic automation solutions is the range of robots from different manufacturers that may already be installed at a customer’s manufacturing facility. Not only is additional space at a premium, but the custom robot arm must be able to integrate with existing automation.
Mecademic: Enabling compact, high-precision automation
Microautomation solutions can provide all the benefits of a robotic automated solution, resulting in reduced cycle times, reduced waste, increased quality control and repeatability and improved overall yield. Mecademic develops the world’s most compact industrial robots, like the Meca500 and MCS500. Designed for performance, reliability and ease of use, Mecademic’s low-maintenance industrial robots are hardware and software-agnostic, and can work with any existing robot installation.
The Mecaportal web interface supports intuitive operation with no proprietary language, complex training or software downloads. It incorporates an autocomplete feature for quicker access to commands and managing saved programs, and enables users to focus on initial configuration and testing rather than struggling with complex programming.
The MCS500 SCARA robot has a 360° range, a 225 mm reach, and 0.005 mm position repeatability. It can be mounted in a variety of positions, including tabletop and upside down. The Meca500 compact six-axis industrial robot arm has 1 µm resolution, 5 µm repeatability, 500g rated payload and 330 mm reach. The Meca500-OB has an optical black surface treatment specifically designed to prevent light interference in photonics applications.
In addition, there are a variety of near-universal compatible end-of-arm-tools including grippers, sensors, Piezoelectric force sensors, vacuum systems, screwdrivers and tool changers that allow you to expand and customize your compact robot arm to get the most out of your investment.
Mecademic has a global customer base and a growing support network.
New markets and applications
Compact robots make automation possible in industries like electronics, medical devices, and optics and photonics. These industries require precision, repeatability and accuracy to a thousandth millimeter or 1μ to 2μ with repeatable results. The challenge for robotics manufacturers and integrators is to deliver the benefits of high-precision robot arms when working with parts the width of an eyelash.
In applications that include alignment, assembly, dispensing, and inspection at a micro-scale, the compact robot arm can operate in tight spaces while offering a 0.005 mm position repeatability. In the optics industry, for example, parts may require different orientations, different assembly processes may require different orientations and even a millimeter of difference between parts can result in failure. Manual assembly is time-consuming; traditional robots do not have the finesse or dexterity. Compact robot arms that operate in small spaces, and are plug-and-work extensions of your existing automation installation offer efficiency, accuracy and precision assembly.
In the electronics industry, products such as earbuds, connectors or implants have many small parts that must be assembled and oriented precisely or the product will fail. Quantum lasers require reliable photonics and accuracy to the 1μ. The Meca500 robot has six degrees of freedom making it capable of extremely precise movements, with repeatability of five micrometers, and one-micrometer position increments making it ideal for optics and photonics manufacturing.
Industries such as technology, wearables, research and academic centres provide microautomation with opportunities to expand and collaboratively innovate.
Space-efficient system design
One of the advantages of compact robot arms is the small overall footprint required to operate it. With embedded controllers and ultra-compact footprints, Mecademic robots allow integrators to build smaller cells and save floor space.
When the Steven Douglas Corp. (SDC) was building a system for their medical devices client, they incorporated the Meca500 six-axis robot into the automation solution which replaced multiple manual processes. The challenge was the assembly required micron-level precision: the clearance between the rivet and the link hole—the two main elements in the components it builds—was a thousandth millimeter. One complete assembly comprised 73 parts: 25 links, 48 rivets and 48 welds. The compact robot solution was able to complete the assembly five times faster with a lean, efficient setup that integrated with the other robotic components seamlessly.
High precision and repeatability
While Mecademic robots take little space, they do not compromise on quality, reliability or precision, providing customers with the ability to scale manufacturing to meet increased demand without compromising quality.
Mecademic’s 6-axis robot, the Meca500 delivers repeatability of 5 μm, resolution of 1 μm, and precision down to 0.005 mm, delivering high-quality output in demanding applications. The Meca500-OB has an optical black surface treatment that absorbs 96.5% of visible light, preventing even minor light interference from compromising the accuracy and safety of optical applications.
The compact size of Mecademics’ custom robot arms can replace complex, custom-built systems. They are hardware and software agnostic and can work with any existing robot system.
In the field of optics and photonics, one of the impediments to scalability and reliability is the accuracy and high degree of precision required. To deliver the accuracy required, the industry relies on expensive high-precision linear motor stages and Piezo-actuated flexure positioners, which have limited flexibility and a limited range of motion.
XVP Photonics is a leader in providing advanced photonic solutions. They were initially skeptical that the Mecademics Meca500 could provide the precision and accuracy required to work as a fully automated assembly for their customers. XVP engineers tested the Meca500 using a high-power microscope and angular resolution assessments using a Fourier bench to test transverse accuracy and compared the results to theoretical calculations to determine which photonics applications the Meca500 could perform.
For critical applications such as TO-laser diode collimation, objective lens focusing onto CMOS sensors, and aligning pre-collimated fiber assemblies, the angular precision of the Meca500 successfully completed the tasks.
XVP determined the Meca500 could be used for photonics alignment in optical systems with focal lengths above 0.5 mm and mode sizes larger than 5 µm.
In addition, XVP developed a photonics assembly application for lens alignment and glue dispensing, and determined that Mecademics solutions could be used for 90% of XVP’s current photonics projects.
Simplified integration
One of the advantages of the Mecademics robots is that they integrate easily with standard protocols and are compatible with most PLCs. They are hardware and software agnostic, resulting in a plug-and-work automation component that requires no custom coding or proprietary programming. It also requires no software downloads, complex training programs or additional options.
Flexible mounting options, including tabletop or upside down further simplify deployment, with the compact robot arm weighing only 4.3 kg.
Lower Total Cost of Ownership (TCO)
Any robotic automation installation represents a significant capital expenditure (CapEx) and operational expenditure (OpEx). A reasonable return on investment (ROI) for most automation solutions is generally 6-18 months in terms of labour savings, increased productivity, reduction in waste, improvements in quality and repeatability.
Since Mecademic compact robot arms are plug-and-work, there is reduced engineering time, low maintenance, and quick user training, which results in lower CapEx and OpEx. In addition, they have a long product lifespan and minimal downtime, which further enhance ROI.
400% Production Growth Through Robotic Innovation
Seymour Advanced Technologies was looking for a comprehensive solution for one of their customers, an ophthalmic pharmaceutical company that had designed a microneedle for use in ocular surgery. They required a sterile solution that could increase throughput while maintaining the rigorous safety protocols required by the medical industry.
The process involved the insertion of a 25 mm long rod into a hollow cylinder with only 60 microns (0.0015″, ¼ to ⅓ human hair) of clearance. It was being completed by hand with the aid of a high-powered microscope, which resulted in output of approximately 63 units per hour. There was also significant needle breakage during the insertion process, creating medical waste.
SEYMOUR Advanced Technologies was seeking a comprehensive solution for one of its customers, an ophthalmic pharmaceutical company that had developed a microneedle for use in ocular surgery. They required a sterile solution that could increase throughput while maintaining the rigorous safety protocols needed for the medical industry.
The process involved inserting a 25 mm long rod into a hollow cylinder with only 60 microns of clearance, which is thinner than standard printer paper. This delicate task was performed by hand under a high-powered microscope, yielding about 500 units per 8-hour shift. The extreme precision required also led to frequent needle breakage during insertion, creating additional medical waste and variability in production.
SEYMOUR incorporated Mecademic’s Meca500 six-axis robots to complete the assembly process. The system uses 3D cloud imaging to detect the physical parts, as well as their thickness, length, and straightness. The relative positional error is then calculated, allowing the robots to be adjusted for accurate assembly.
By incorporating real-time evaluation into the programming, the robots achieved 97–100% autonomous operation with virtually no maintenance required. Since its implementation, throughput has increased by 400%, enabling SEYMOUR’s client to scale production reliably without additional labor or floor space requirements. In addition, the compact Meca500 robots reduced system costs by nearly 50% compared to traditional automation systems while maintaining the strict precision required for medical device manufacturing.
Supporting integrators: The Mecademic Integrator Program
Mecademic believes strongly in partnering with integrators to build a successful microautomation network. As part of that commitment, the Mecademic Integrator Program is a structured program connecting certified integrators to new business opportunities.
Our integrator certification program is designed for custom machine builders and systems integrators who specialize in compact automation solutions. We provide certification including extensive technical training on Mecademic’s ultra-compact 6-axis and SCARA robots, participation in partner activities, and showcasing Mecademic robots. In addition, certified integrators receive product updates to keep the integrator certification current, and receive dedicated support.
Some other key benefits include:
- Lead transfers: real projects through referrals based on region, industry, and proven expertise
- Discounted demo units
- Lifetime volume pricing
- Co-branded marketing visibility through case studies, trade shows, and promotional content
- Free training and technical support, as well as product updates to always stay current
- Direct line to Mecademic’s applications and support teams
- Extended warranty
- Listing on Mecademic’s website
Conclusion: Compact robotics is the future of machine-building
While the benefits of robotics in manufacturing have been proven to be beneficial, there are limitations to the type of projects that traditional large robotic automation solutions can complete. Microautomation offers integrators access to new industries, better system designs, greater precision, and reduced costs. The small footprint of compact robot arms does not require large reconfiguration, and can perform tasks in industries such as medtech, optical and photonics, academic research, biotech and pharmaceuticals that have been limited in the type of automation due to the precise nature of the production.
Mecademic six-axis robot microautomation solutions are hardware- and software-agnostic, easy to learn and operate and the Mecaportal allows for ease of use, real-time information and intuitive programming.
Mecademic provides the tools and support to help integrators succeed in this fast-evolving landscape. Not only can custom machine builders and systems integrators become certified Mecademic integrators, they can join the Mecademic Integrator Program to become a certified partner and receive referrals based on region, industry, and proven expertise, updates on products to stay current, co-branded marketing opportunities such as case studies, trade shows and promotional content, and a direct line to technical support, product discounts, and a listing on the Mecademic website.
Microautomation robotic solutions can address the challenges of precision, repeatability, and a smaller footprint for industries that have been unable to take advantage of all the benefits traditional robotic automation can provide. Mecademic compact industrial robots provide maximum efficiency, even when space is limited. These plug-and-play micro-automation robots are designed for component manufacturing, optics & photonics, electronics, medical devices, biopharmaceuticals, and research centers.
