Doming imparts a 3D effect on a 2D surface. Rigid molded parts are often domed to imbue a "jewel-like" quality to an emblem or logo. Domes can also be a key part of optical assemblies, in effect becoming lenses for LEDs. Frequently, domes are formed on label stock in a converting process. Some label dome applications are forced to ensure that the carrier for the label stock has a low surface energy and the label itself has a high surface energy to make up for poor machine precision with better "wetting" of material. When precison is required, New Precision Technology's CP16 and ICP platforms are up to the task, easing this requirement.

    Traditionally, on/off valve controls forced the end user to compensate for the difference in time between when a dispense valve turns on or off and the corresponding point at which material starts or stops on a substrate. Now, through a simple calibration procedure, this concern is another that is relegated to the history books. The calibration procedure helps the end user make a one-time measurement of the time and distance between valve "on" and the start of the gasket as well as the valve "off" and the end of the gasket. Now it does not matter if you are dispensing at 1"/second or even 20"/second, the gasket will start and stop at the programmed points.

    Solid objects can be cut and placed using a pick-and-place head. The most common tool is a rigid or flexible gripper, but picking can also be done using suction, static electricity, and electromagnets. We commonly integrate Component Feeders into our systems to ensure high volume operation. Feedback sensors on grippers and slides ensure that all steps of the process are monitored for successful part runs.

    Soldering machines consist of a heat source, a solder-paste dispenser or wire solder feeder, and an optional fume extractor. The heat source is either a soldering iron or a hydrogen flame. Many applications also include pick and place, inspection, or testing appendages.

    Our systems are used to perform a variety of tests. Assemblies can be pulled from matrix trays and leak tested. Circuit boards or mechanical assemblies can be checked with Banner or Cognex vision systems. Quality can be verified with submicron accuracy using laser based measurement systems. While these tests can often be performed in conjunction with other operations, it is often best to dedicate a machine to high resolution inspection as vibration can have a negative impact on high resolution accuracy.

With these high speed tools and techniques it becomes realistic to execute real time, in line gasket measurement during production. Gasket measurement can be conducted in either a quantitative sampling style (does the height at this point fall within the window) or in a qualitative, signature analized comparison to a gold standard (to what degree does the current gasket match a trained sample).

    Not all parts are created equally. We go to great efforts to see that parts are handled with care and efficiency.

    In this example, the CP16 platform has been configured for a custom soldering application. Parts are fed from a vibratory bowl in a left and right orientation. The top-heavy nature of the part means it needs to be flipped 180 degrees upon removal from the dead nest before handoff to the pick-and-place head. Solder paste is dispensed on the circuit board beforehand and the parts are placed through slots on the board. The brass parts present a sizeable heat sink and hydrogen gas, obtained from cracking distilled water, is burned and the heat is transferred to the brass. The heat travels through the brass and the thermal mass of the part helps create an ideal profile to reflow the solder paste.

    Injection molded thermoplastic parts typically display parting lines induced by the mold components where the mold segments come together during the molding of the part. This line can be more or less severe depending on mold wear, clamping pressure, mold cleanliness, and a host of other factors. In many cases the resulting excess "flash" at the parting line can cause parts to fail to meet specifications. In particular, molded parts that subsequently go through chrome plating processes can be a problem as the plating process serves to magnify the flash, potentially yielding sharp edges at the parting line. NPT has developed a system that is capable of analyzing the height of the parting line flash and through focused application of a stream of hot air, our system can reduce the height of parting line flash by at least 50% and often - depending on the nature of the thermoplastic we are working with - cause the flash to be entirely removed.

    The Spraying, Conformal Coating, and Masking category describes those applications that require some degree of surface area coverage for protective or decorative reasons.

Many coatings are sprayed, but they can be dispensed by many other methods - dipping, vapor deposition, and even brushing. Spraying now not only includes conformal coating, but also the application of greases, lubricants, and slip coat products. Spraying has an advantage in that a large area can now be coated quickly, but the disadvantage is that it operates well only in a narrow viscosity range. Ideally materials from 1 to 1000 centipoise work best, although in unique cases 12,000 and 14,000 centipoise materials have been sprayed in the past. These materials have included greases such as various Nyelube products and even ceramic slurries. The greater the viscosity, however, the more difficult it becomes to achieve good edge definition with spraying. In these cases it makes sense to mask, spray, and then remove the mask. With today's UV curable masks, these multiple operations can often be achieved on a single machine and in a single program cycle when on-board UV curing is brought into play.

Conformal coatings are used to protect electronic components from the elements, insulate electronic components from physical(G shock) and electrical stresses (ESD), and sometimes to gain regulatory approval. Coating materials can be solvent laden acrylics, water-borne materials, two part materials, UV curable acrylic materials, UV urethane materials, and silicones - both solvent born and moisture cure RTV forms. All forms have specific advantages: Moisture cure silicones are low or no VOC materials but can have maintenance issues. UV curables have no maintenance issues but require UV curing hardware and a little more caution when handling. Always examine the MSDS of any potential material candidate to be sure your production situation can accomodate the needs of the material.

Masking can be accomplished as either a spray or a continuous solid pattern dispense. The issue that typically differentiates masking from other coating applications is the fact that at some time during a process a mask is intended to be removed and then leave little or no residue. The removal can be a physical unpeeling or a chemical dissolving, but in either case the mask has to come off!

There are key tools to help close the loop on masking applications. Material pressure feedback and compensation, temperature control, and laser film measurement are all feedback elements to be considered to achieve a consistent, controllable process. As well, with those applications that use dispensing tips, needle tip calibration and height sensing become critical control issues.

Offline programming tools that can accept Gerber files or DXF files and then help to create pattern dispense paths automatically are huge time savers. Without these tools, machine programming and the subsequent adjustment process can consume hours of valuable machine time. With these tools, it can take minutes if not seconds to generate coating programs - even for multiple dispensing heads. Revisions become much less complicated as now the pattern program relates to objects to be avoided versus non-descript pattern commands.

New Precision Technology has been providing conformal coating solutions since 1995 with our CP16 platform. Our platform excels when dispensing moisture cure silicone coatings, UV cure coatings, slip coats, greases, and other materials. Please do not hesitate to contact us with any questions and applications!

    CP systems can employ a number of marking methods. Whether filling in injection molded parts with various paints and inks, utilizing high speed reciprocating carbide marking pins, or employing an ink jet head to print text, the CP platform has the tools to ensure marks are placed accurately and consistently.

    Gasket dispensing describes the extrusion of a viscous fluid that upon curing forms an elastomeric seal. After cure, when a mating surface is applied, the joined parts typically meet some requirement for a barrier against liquids or gasses. Commonly referred to as Form In Place gasketting (FIP), this process avoids the cumbersome aspects of handling and placing cut gaskets and affords the flexibility of many variations without having to inventory cut gaskets. As long as process issues such as part variations, material rheological variations, and operator induced variations can be addressed, FIP gasketing can be a production floor operation that adds value to the bottom line.
Classical gasket dispensing solutions include key process control elements such as needle tip calibration to ensure dispense tip location, height measurement (tactile , laser, or ultrasonic) to rule out part height errors, temperature control to lock in consistency, vision for part location and quality verification, and the software tools that make these elements work together so that they augment each other become more than the sum of their parts.

    Sometimes the application requires that a part be handled only on a face opposite the one that is being presented to the machine. This example utilizes a vertical magazine feeder that isolates one part in such a way that there is an opening underneath the drawer for a fork pick head to lift out the part from the bottom face. It is then placed into the machine work area nest for treatment. Sensitive faces of substrates can be completely avoided using this technique.

    Dispensing discrete dots of material is one of the most basic of dispense applications and yet still manages to present its own unique challenges. The smaller the dots, the better the process control must be. Where applicable, a standoff-foot can help yield consistent results, but often that is not a viable solution.
Dots as small as 300 picoliters are possible, depending on material rheology. The smaller the target, the more critical the height above the substrate, especially when no standoff foot can be used. Precise information regarding tip position and substrate Z location (as well as X and Y) become crucial for success. Vision alignment becomes key for high speed, accurate throughput.
Typical dot dispenses include SMD adhesive, genetic (DNA) arrays, microfuidic test slides, solder paste conductive adhesives, epoxy microdots, grease lubricants, CAs, and many others.
At a certain point a dot dispense ceases to be a dot dispense and transitions to a potting dispense!

    In this example we are converting XYZ coordinates imported from a DXF file to YZ and theta coordinates only when the RUN button is pressed. The advantage here is that all of the traditional tools still apply: needle tip calibration offsets, height measurement offsets, and laser programming tools loose none of their value despite the radical shift in coordinate systems.

Properly applied, it becomes possible to dispense gasket compounds with less than +/-0.0005" (+/-12 micron) height variation across the entire gasket. The scan images illustrate the consistency and of course also point out our ability to verify the consistency!

    In this example we are dispensing on a blank carbon plate to illustrate the benefits of standoff foot dispensing. The paths are programmed as XYZ coordinates and then at the moment of dispense, these are instantly converted to Y, Z, and theta coordinates to keep the standoff foot to the inside of any given polygon. The result is that at no time does the foot cross over the gasket and the gasket height is 0.020" or 0.5mm tall. Because we maintain full axis control, when we lead out at the end of the gasket, we can spiral inwards to prevent the "Hershey kiss" effect when pulling away from the main body of the gasket.

Also note that the gasket would maintain its precise height despite any part warpage up to +/- 0.5" or 12.27mm. The compliant foot rides on a linear bearing with a total of one inch of stroke.

Not all applications are ideal for a compliant foot configuration. The foot itself has the potential to abrade the substrate on which it is riding. In most cases this is not objectionable as the down force of the foot can be controlled to minimize damage or the fixed sliding point can be replaced with a radial bearing or wheel. In those cases where any abrasion may lead to unacceptable surface damage, we would encourage you to consider our height measurement sensing system, CPOTHS.

    Conductive ink, gasketting, and shielding applications benefit a great deal from the synergy of motion, sensing, and software. IMAGE ONE below shows traces formed with conductive inks on polyester with an LED placed directly on the ink to form the circuit. Subsequent application of a conformal coat serves to secure the assembly. Note the soldered wires on the polyester. Video one shows resistance traces precisely formed with the benefit of accurate height measurement. Video two shows sprayed RF shielding applied with minimal waste of material. Video three shows a silicone RTV filled with silver used as an EMI shield compound on cell phone housings.

    At 24 inches per second of travel, this CP24 yields terrific throughput! The head dispenses "pats" of hotmelt PSA adhesive to help fixture products on a plastic sheet. The sheets are held on with a vacuum system that detects when a sheet has been removed and when a new sheet has been placed on the pallet. The high speed and the vacuum system combine to yield a throughput rate of less than eight seconds per sheet!

    Hot melt applications are cost effective solutions to assembly process difficulties. Rapid dispensing coupled with what are typically lower cost adhesives, hot melt processes can have very good returns on investment.

Because of the high temperatures seen by the head - temperatures that would otherwise damage the motion components of the robot - excellent heat isolation is necessary. While some of these example videos show an open head design, this is only for video purposes. Heads are shrouded when in production.

    This system incorporates our ICP platform that can work over dials and conveyors. In this case, parts are presented to the machine via a conveyor and are fixtureless. The onboard vision system performs rotational/translational re-alignment using two openings in the part to properly align the program to the part. This ensures a good spray every time, minimizing overspray that could otherwise contaminate a class-A surface. It also includes a spray-pattern sensor, which verifies fluid flow prior to each cycle.

    This machine populates keyboards with a large number of switches. A steel frame houses the machine and vibratory bowl on a common base. To ensure that the keyboard is filled quickly, a magazine travels with the head to minimize the need to go back to the bowl for new parts and saves time. An escapement built into the head loads 25 parts at a time and then rapidly inserts them into the circuit board.

    In this application we manipulate a stack of metal plates.

    CP systems can employ a number of marking methods. Whether filling in injection molded parts with various paints and inks, utilizing high speed reciprocating carbide marking pins, or employing an ink jet head to print text, the CP platform has the tools to ensure marks are placed accurately and consistently. Markings can be conformal coated as well. Video one shows marking in the case of a flat object and video two shows the same marking done in a vertical orientation.

    Eight diodes are oriented and placed into a ring using a vacuum-based end effector. The vacuum foot has a theta axis mount that allows for different orientations of the parts. A compliant, spring-loaded feature of the vacuum foot compensates for height differences on the substrate without damaging the components.

    The CP16 can be configured for hydrogen gas flame soldering. Distilled water is electrolyzed into its hydrogen and oxygen components, eliminating the need for stored hydrogen. This process also results in a clean fuel - no sooty buildup! The resulting gas is put through a ruby orifice 0.004" in diameter, yielding an invisible flame perfect for small solder joints.

    This machine receives switches from a vibratory bowl feeder via a horizontal track attached to the feeder. The flexible gripper picks the switch up, straightens the leads, and then checks the continuity of each switch. If the switch is good, it is inserted into the switch socket on the board. If the continuity test fails, the switch is placed in a reject bin. This machine also utilizes a theta axis for the gripper to accomodate different part orientations on the board.

    Conformal coating is a standard application for NPT. Whether UV or silicone, the CP16-3 and CP16-4 excel in maximum coating utilization, minimizing waste of material. Equipping the unit with digital pressure sensors for material and atomize pressures, laser-based coating thickness measurement, and spray pattern sensing all serve to reduce operator error and ensure consistent throughput. Multiple valve types and theta axis mounts for valves can be used on one machine to handle any obstacle on the substrate. UV cure units can also be integrated directly into the work envelope, to provide a fully cured product upon pattern program completion.

    New Precision Technology equipment can be outfitted to handle larger meter-mix heads for 2-part dispensing applications. A stronger z-axis stage, geared x-axis stage, and larger gantry shafts enable the use of heavier dispense hardware. A recommended needle tip calibrator will ensure that the necessary meter-mix tube replacements will stay on the mark every time. Dual-pack cartridge dispensing is a dispensing technique that avoids the breakdown and clean-up time of dedicated material lines.

    Application development is our true forte. With any application, our standard product lines present only one phase of any automation project. We are able to offer our years of accumulated experience in manufacturing processes, assembly materials, and material handling with every project. Our goal in robotic automation is to reduce the propagation of uncertainty in client applications and thereby greatly increase part yield.

    We fabricate our designs in-house. This gives us complete control over cumulative tolerance stackup and overall system precision.

    Installing, Training, and Warranty.

    This category of production equipment is extremely versatile. We have converted soldering systems to gasket dispense systems, coating systems to polishing systems, and everything in between. Why? Because the only constant is change. Most product production runs come to an end and rather than letting the machine collect dust, many customers opt to send us in the equipment for reconfiguration. This is a cost effective alternative. In the fourteen years we have been producing the CP product line, several units have actually been re-manufactured more than once.
Sometimes companies will develop excess capacity and in those cases we will bring in machines on consignment. This gives a prospective customer a chance to purchase a state of the art, re-manufactured system and save roughly 25% off of the cost of a new machine. Re-manufactured machines are typically offered with a one year warranty.

    The very first thing we do at New Precision Technology is study the assembly situation. This includes not only the application, but also the level of integration, surrounding plant resources, and operator personnel. We can also utilize our cumulative experiences with processes and make recommendations on materials, curing, packaging, and fixturing. We have likely handled many other types of problems similar to yours, and we can provide a feasibility assessment for the task you are proposing.
Our goal at this stage is to gather enough information to make our base platform selection - benchtop, stand-alone, pallet-conveyor, in-line conveyor, batch-dial, or in-line dial.

    We offer a number of feedback systems that serve to minimize the impact of production level variability. NPT tools compensate in real-time for part height variation, material rheology changes, facility environmental changes, and operator-induced variations to minimize their impacts and greatly boost part yield versus traditional "CNC" automation.

We can also offer useful Graphical User Interfaces for upkeep, inspection, and programming of our machines. A real-time graphical representation of what is being scanned, weighed, or sensed can provide instant notification to system managers and operators if what is being analyzed exceeds preset boundaries.

    We design and fabricate our machines in-house. Our CNC equipment enables us to efficiently fabricate everything from motion components to fixtures. This gives us a level of flexibility that is unparalleled in our industry. This level of vertical integration is something we regard as essential to providing best fit solutions.

    If after placing an order, the project changes, we will gladly accomodate your customization needs. Once the machine is finished, we will send videos, pictures, and show demonstrations of the machine working in the way you expect.

    Our true strength as a company is the fact that all of our systems ship turn-key. Apply power and air, and most applications are in production five minutes later. Even complicated systems are engineered to minimize the impact on existing production lines. In the case of in-line systems, we have even duplicated a conveyor section used in production to be certain of minimal line down time. In one time-critical application, we only needed to pause an automotive component assembly line for fifteen minutes to convert a manual process to an automatic one.

    Although our machines typically come pre-programmed as part of an overall turn-key system, we offer training sessions that cover programming for a broad range of applications and we share our experiences that minimize operator training, minimize part defects, and maximize your return on investment. We have a simple pattern programming scheme that does not require G-code knowledge or specialized training. We also have available tools such as a DXF file reader and a Gerber file reader that allow simplified importing, and a coating application assistant that dramatically reduces programming time for conformal coating and paint application programs.

    Once a production run has finished, our machines can provide additional return on investment. Send them back to New Precision Technology and we can retool our machines for a new product.

    While we use the best materials possible (our bearing life calculations project 14 years MTBF), a manufacturing environment can be harsh on equipment. As a result, we offer a variety of plans to detect problems before they stop your production. We offer various plans allowing you to inspect, restore, and even reconfigure used machines, giving you a huge return on investment.

    Production runs come to an end and sometimes it becomes necessary to find a new home for your equipment. Because our standard platform has been around for a long time, we can offer a number of ways to turn old equipment into cash. We often take equipment in on consignment, which allows us to rebuild it and presents an opportunity for a lower cost alternative to a new system.

Current systems available:
CP16 with diaphragm valve and pressure pot.
CP24 system with hot melt head
ICP1212 system

Please inquire for specific configuration needs.

    It is now possible to monitor factory dispense productivity across the web. Accessed through secure socket layer with 128 bit encryption, the members portal of the newprecisiontech (nptinc) website can provide detailed, up to the minute information on good parts completed versus bad, idle time versus down time, and operator productivity. This information can be used for purposes of line balancing so that underperforming hardware can be recognized and retasked, shift productivity assessment, and machine mechanical state (so that maintenance can be consistently scheduled). As well, it enables staff at New Precision Technology to monitor maintenance and assist with optimizing program efficiency.
ALL FEATURES ARE END USER SELECTABLE AND THE END USER CAN LIMIT ACCESS TO ANY FEATURES

    Patent #'s 10525627 and 10220559
Foam in place gasketing is a versatile process, but requires very expensive equipment. Just the foaming equipment is typically $50,000 and when all of the various required components are in place the pumping equipment can spiral to $100,000 pretty easily. While there are PU foam systems that are less expensive, so far we have found them to be maintenance intensive. Ideally, we would like to have the features of foamed gaskets without the upfront, steep hardware costs or maintenance headaches.
Hollow gaskets can fulfill many of the roles assigned to foamed gaskets. These gaskets can be produced using simple materials such as silicones and the pumping equipment is almost an order of magnitude less costly.
Because these are extruded gaskets, many unique profiles can be applied and we are no longer constrained to simple circular sections with the typical height:width ratios of 1:2 or at best 1:1. Instead, we have produced ratios not only of 1:1 but also up to 1.5:1. The profiles can be other than the classical circular section such as triangular, rectangular, "M' shaped, or whatever best serves the sealing need.
These gaskets will have one or more hollow segments and the segments can be filled with air, nitrogen, or even conductive polymers.
These gaskets can even form sealed channels that can transport air or other fluids in a specific pattern, thus forming heat exchangers or allowing seals that can be pressurized AFTER the mating surfaces have been engaged.
Hollow gaskets have several advantages over traditional foamed gaskets:
1) Tall profiles can readily be formed. Current testing has produced 0.5" tall (12.5mm tall) seals.
2) Because of the extrusion process, the height of the gasket can be held to a very high tolerance.
3) Can be easily compressed more than 60% of overall height with light compressive force
4) When compared to the traditional 1:2 (H:W) profile of a foamed seal with 50% foaming, hollow seals use 47.5% less material.
5) When compared to the traditional 1:2 (H:W) profile of a solid material seal, hollow seals can use 74% less material.

In one particular sample case the overall seal height was 0.48" (12.98mm) and the weight of material per inch was 1.56g.

One issue to keep in mind is that these seals are extruded horizontally onto a surface. As a result, ideal applications are not endless! We can only approximate endless by running the start and stop parallel to one another as seen in the 13mm tall sample photo below. On the other hand, this method allows precise gasket extrusion with many possible profiles.

    Heads are our term meant to include any selectable device that would be mounted on the z-axis of the machine. Valves, lasers, grippers, LVDT probes, cameras and more fall into this category.

    In addition to performing a function, our machines may be installed with one of these useful feedback options.

    Software represents one of the key elements to successful automation. Whether the user is a line operator, maintenance technician, trouble-shooter, or setup programmer, the software must present the proper tools for each of these roles. Our in-house software development team collaborates to incorporate unique, time-saving ideas with each revision.

Another unique aspect of our software is that we do not store our pattern programs on a separate controller. This enables us - unlike some competing machines - to incorporate sensors and systems in real time. Robust, real-time control enables us to account for process variables that would be cumbersome to manage with a CNC-type control.

    The CP and ICP platforms comprise the foundation of our automation solutions. Designed to maximize flexibility, accuracy, and speed, these systems continue to provide value for an extraordinary length of time. With a bearing design life measured in decades, minimal maintenence needs, and efficient system design allowing rapid routine maintenence, these systems can be reconfigured for new applications many times throughout their useful lives.

These systems have been through third party evaluation for conformance to CE Emissions and Immunity test specifications. Specifically, these platforms meet EN 61000-6-2:1999 Electromagnetic Compatibility (EMC), 12/CIS14 CISPR 14-1 Emissions, CISPR 11 Group 1 Class B for industrial, scientific, and medical equipment.

    Our most common head is a valve dispense head.

    Automated quality control is realized quite effectively through our direct machine control model. This enables us to further close the process control loop between sensing and dispensing, allowing the robot to compensate in real-time for process variations. Trainable sensor models can perform signature analysis and allow precision sensors to deal with production variations and still prevent false negatives so that the positives are only those parts with valid problems.

This concept addresses something that is an issue with common, off the shelf (COTS) SCARA or 6DOF robots: dealing with process variability. Without the automation having the capability to adjust automatically to variations in parts, materials, and environment, you need to either accept looser tolerances or greater reject counts. With adaptable automation, there is now a governing automated ombudsman that can fix some of these issues, resulting in higher yields.

    Head mounted sensors, both contact and non-contact, provide real-time verification of production process parameters.

    Part measurement sensors are used to compose, confirm, and calibrate parts to the machine measurement system. These systems reduce the impact of part-to-part variations, whether those variations are due to fixturing tolerances or simply the part itself. While they may impose a small time penalty, they tend to greatly reduce what would otherwise be scrap and rework.

    Tip Calibrators help close the loop to the production part and eliminate the variability that comes from operators installing a new dispense tip.

    Perhaps the most fundamental dispensing valve, the needle valve is the workhorse of the dispensing toolkit. This option includes the valve, mounting, and actuation control. If you will be using this valve alone, or your dispensing needs revolve around flat objects, this option will suffice. The CPONVS option includes a pneumatic selector slide which facilitates gang mounting of a variety of tools

    Perhaps the most fundamental dispensing valve, the needle valve is the workhorse of the dispensing toolkit. This option includes the valve, mounting, and actuation control. If you will be using this valve alone, or your dispensing needs revolve around flat objects, the CPONV will suffice. The CPONVS option includes a pneumatic selector slide which facilitates gang mounting of a variety of tools.

    The ICP is our in-line model for working over conveyors or dials. This particular design has a number of advantages over competing systems:
1) The design has the characteristics of any cartesian versus SCARA multiple DOF arms - mainly that these minimize motor torque requirements.
2) In conjunction with item #1, the lower torque also means the bearing systems are subject to lower wear and tear, increasing system longevity.
3) The design completely encloses the motion elements, potentially maximizing safety.

    The CP16 is our standard 16x16 work area base.

    The CP24 is our larger 24x16 work area base.

    This software allows the automated analysis of profile scans. It collects data from a laser system traveling through a region of interest, applies mathematical algorithms to extract features of interest, and reports not only the traditional pass/fail, but also how close we are to pass/fail. This enables our control software to modify machine parameters in response, which allows for the constant improvement of the process in response to environmental and rheological changes.

    LVDT probes (Linear Variable Displacement Transducer) provide a robust solution for precision production measurements. These units take a given range and provide a measurement based on the capabilities of the analog to digital converter. For example, a probe with a half inch stroke and a 12 bit (4096) A/D converter yields a resolution of 0.000122" or 0.3 microns. Because of their simple design - a steel core in a coil, basically - they withstand the rigors of production life.
The resulting benefits are real-time adjustment of pattern programs that accomodate part variations preventing scalloped or otherwise non-conforming gaskets. These units can also be used to assess (and reject if necessary) parts with missing subassemblies. They can also be used with arrays of parts that will allow a complete array to be processed despite missing array elements.

    Our Operator Screen interface has specifically been designed not to overwhelm the line operator with too much information and yet present things simply enough that a setup technician need not be constantly on call. Small changes to a current program's position and dispense rate can be made quickly and easily with this interface.

    This unit uses a retro-reflective laser and sophisticated software to determine the actual dispense tip location in XYZ space. Unlike many units, the software calculates the effect of any bend and interpolates the actual tip location. Because of this interpolation, which is done on both sides of any axis scan, this unit holds +/- 0.002" (+/-0.050mm) locational accuracy.
Additional features include the ability to scan taper-tipped nozzles, and a drop-through design that protects the optics from adhesives and other liquids.

    One tool used to reduce the impact of continual production variations is the automated vision system. Capable of finding the center of features within milliseconds, this tool provides rapid part alignments, compensating for both rotational and translational offsets. In the given example, the part is simply placed on a conveyor belt and the system can align the part automatically.

    The website has undergone an extensive update.

    Excellence in Industrial Automation through Semi-Custom Design - Made with pride in the USA!

    New Precision Technology has developed in-house a new dispensing technique designed to deal with part height variation as a production issue.
It is normally considered impossible to dispense a closed shape (circle, square, etc) using a standoff foot as the foot will run through the gasket at some point. By rotating the part beneath the dispense valve, we avoid complicating the dispense valve with additional hardware. This technique lends itself to precision gasket formation for fuel cells, LCD screens, display terminals, and any flat structures requiring precision gaskets or adhesive seals.

    New Precision Technology provides semi-custom automation solutions that utilize our expertise in dispensing, soldering, coating, gasket extrusion, pick & place, vision inspection, and sensing. Vertical integration and proven base designs ensure we provide best-fit solutions for your assembly projects. Flexible components and robust command sets yield a renewable asset - essential qualities in today's world of limited product lifecycles.

    New Precision Technology, Inc. was founded in 1991 by Axel Van Briesen with the goal of supplying software and hardware tools to streamline the demands of programming, equipment setup, and running automated circuit board assembly equipment. Engaging in this competitive, exacting industry honed our skills to :

• analyze a manufacturing process for automation opportunities
• evaluate required working methods and systems organization for planned automation
• design dedicated fixtures for a wide variety of work pieces
• integrate equipment into existing manufacturing structures and procedures seamlessly
• implement easy-to-use operator interfaces (both equipment and PC based)
• meet the need for high volume and high accuracy in rapidly deployed systems
• understand the need for and produce clear documentation

In 1994 a client approached us to design a new piece of equipment with the stipulation that it be based on a compact, bench top Cartesian robot platform. Sensing the potential to bring our existing knowledge to a whole new platform, New Precision Technology, Inc. opted to design a flexible system from the ground up. This enabled the company to customize the base unit to meet the precise needs of a host of new manufacturing tasks. This was the inception of our CP platform. By the end of 1995, New Precision Technology, Inc. had provided units for soldering, dispensing cyano acrylates, dispensing gaskets, and spraying conformal coatings.

In subsequent years, we began developing the tools that address the process variation concerns so prevalent even today: needle tip calibration to address inadvertent changes in needle position, height measurement to address part height variation, vision to address part rotation/translation errors, laser triangulation sensors to address liquid level concerns, and others. These systems are now robust, mature sensing subsystems that can endure the rigors of production environments.

A new line of equipment dubbed the “ICP” made its debut in 2003. This allowed New Precision Technology, Inc. to address the needs of the in-line automation world with a system designed to work over index dials, conveyors, and shuttles. The ICP systems leverage all of the advantages of the CP systems – sensors, software, and tooling – and allow the unattended automation world to address product and process variations. In today’s exacting world, it is now crucial that each step in a manufacturing process yields results 100% within tolerance specification. It is no longer sufficient to catch non-conforming parts.

In 2006, New Precision Technology, Inc. began work on a massive software project to integrate these subsystems, leveraging the power of modern interfaces, USB devices, and the Microsoft Windows platform. Today, these subsystems are capable of working in concert, and the benefit is greatly simplified operation. No longer must material pressures be adjusted to maintain part consistency, no longer must parts be precisely fixtured with expensive custom fixtures, and now gasket dispensing is a consistent profit center rather than an operational liability. Advances in usability - automatic CAD conversions, automatic performance tuning, and simplified maintainability including automated diagnostics with internet/machine connectivity - serve to massively accelerate the returns our clients get for their investments.

Current research includes new efforts in 3D scanning, real-time rheology assessment, enhanced dispensing control and further simplification of manufacturing process technology. New Precision Technology, Inc. continues its relentless pursuit of process advances that enable our clients to maintain a competitive edge in this global economy.

    This new subsystem allows DXF files to be read, layers and contours to be selected, and order of contours to be determined. It also allows for repositioning of contours to get the best inital approximations. Conversion from english to metric is also accounted for. The DXF reader allows for NPT programs to be built quickly and automatically.

    This is a laser-based gasket presence sense system that can work in conjunction with dispensing on ICP and CP systems by New Precision Technology. Based on a "learning" process, the software automatically builds a model of the part and compares the current scan to the model. If the scan fails and Quality Control determines it should not have failed, the scan is incorporated into the "passing" category and similar parts will not fail on future scans. Scans are possible at 5"/second to 12"/second and beyond, depending on the minimum defect to be captured.

    Using a variety of cost-effective laser systems, New Precision Technology can now offer 3D mapping of surfaces, often along with dispensing on the same machine! Because of the inherent stability of the CP split axis design, it is possible to get high resolution (1 micron and less depending on laser) scans using our standard platform. The laser mount can be outfitted with a theta axis as well. This allows the laser to be toggled from specular to diffuse mode and angles in-between. This is very helpful when dealing with highly reflective targets. Various tools to aid meaurements are also available including : color scale manipulation, filtering of noise from laser data, automatic peak (and inverse peak) searching, and more.

    Our newly developed standoff foot gasketting technique has yielded measured results showing gasket height being held consistent to +/-0.0005" overall. Using our in-house scanning software package which can take 2D and 3D measurements, we have verified that these unprecedented results are now a production level reality. Material rheology and environmental factors will still contribute to the overall repeatability of gasket height, but this technique reduces the impact of mechanical positioning by an order of magnitude or better.

    We create automated machines from a dynamic Cartesian Placement base. This base best combines speed, accuracy, and mobility with customized tooling and programming. Our goal is to install and maintain machines for our customers.

    The CP System naturally allows us to offer affordable automation solutions. Please contact us and tell us how we can help and we will be happy to give you a quote.

    We are located at 500 Bursca Dr. Suite 503. Bridgeville, PA 15017. You can find directions to our factory here.

    Our Scanner Screen has a method of using a dispense head in addition to a scan head. When a cycle is programmed with both types of heads, the system can be made to first dispense material and then follow up with a scan. When compared against the trained model, the dispense can be judged as a pass or fail immediately. Quality Control is built right into the dispensing system!

    NPT re-introduces our LC16-8 gasket dispensing machine. Now configured with efficient pattern generation software, setup and productivity have been radically enhanced. Load in gerber photoplot data or DXF information and it now becomes a matter of seconds to select a desired gasket dispense path and even specify automatic lead-in and lead-out path generation. With a standard grid fixture, gasket dispense valve, and 1/10 gallon (300ml) "caulk" tube cartridge holder, this is a complete system. Our LC line comes pre-programmed with several examples that act as tutorials when creating your own production patterns. If you require a system pre-programmed with your production parts or you require additional dispense heads, sensing systems, or axis controls, please consider our CP line of equipment.

This system is compatible with the following materials:
1) Loctite 5910, 5950, 5960 and others - we recommend our CP line with ram pump for 5900 due to high material viscosity.
2) Dymax GA-103 to GA-108 materials.
3) Novagard 400 series moisture cure and 800 series UV/moisture dual cure materials
4) Most materials below 500,000Cps or an extrusion rate of 300g/min or faster.*

For specific materials please call to confirm compatibility.
* Some coatings and facilities may require hooding or duct work to extract any fumes from the workspace. Please take this into consideration when siting equipment.

    Our unique 5-step Sales Process will ensure that you are completely satisfied with your machine.

    The first step in creating an application is a firm understanding of the requirements of the project. The easiest way is to Call Us at 412-596-5948 and one of our engineering representatives will gather the necessary information to continue the process.

    Our unique 5-Step Application Process will ensure that you are satisfied with your machine.

    Once the requirements are received, we can begin the Free Demonstration. Not all applications are created equally, and the purpose of the Demonstration is to prove that our machines can produce parts within the requirements.

    Once we've received approval, we begin to manufacture and program a new machine dedicated to producing the results within the requirements. Because the design is based on one of our machine platforms, the construction moves quickly.

    Acceptance is one of the most important parts of our application process. After the machine is built, programmed, and producing parts, we will provide video, media, or a plant tour to familiarize you with your machine. We will make minor changes to both the hardware and the software until you are completely satisfied.

    Applications change, manuals are lost, and software updates are constantly being made. Even after the machine has left our facility, we are still working for you. A skilled support team can help you with problems or spare part replacement years after the original purchase. We also retool and refurbish old machines to ensure they are up-to-spec for a new application.

    Each software package comes with the User Screen, a simplified interface developed for the production floor. Important tools common to daily operation are readily available by mouse, keyboard, or joystick. Offsets, flow rates, and rotations are a breeze with the large text and menu-style buttons. Simple commands for Tip Purge and Tip Calibrate can be made available depending on the setup of the machine. The large Pattern Preview offers even more visual feedback.

    The Pattern Preview has become a software standard, giving a top-down view of the work area and the current pattern. Pattern segments are easily recognized through selection highlighting. A labeled I/O set and real-time position feedback shows the current position and state of the machine at all times. A modest zoom function and alternative views offer a bigger picture of the machine's actions prior to execution.

    A quick diagnostic check is now routine prior to any pattern execution. The machine automatically searches for possible error conditions based on the specific machine setup. All errors are reported to the user, allowing a manual bypass or offering a course of action. In special cases, a more detailed check may be performed as a method of preventative maintenance and machine optimization.

    Replacing dispense tips is a production reality, but the ensuing pains of calibrations are not with the new Automated Tip Calibrator. At the touch of a button, any tip is automatically calibrated to an accuracy of +/-0.0005" (13 microns), regardless of length or style. Height probes and other machine heads can also be calibrated, simplifying the entire machine calibration to a single button-press.

    Materials are inconsistent and are dependant on hundreds of uncontrolled factors. With one simple tool, most materials under any condition can be dispensed to within +/-0.005" (130 microns). The Material Profile Station measures the actual dispense, automatically adjusting several dispense variables to keep the dispenses within the desired specifications. Factors like temperature, specific gravity, and batch variation are concerns of the past with the new Material Profile Station.

    Parts and fixtures will vary, but the results will not. By scouting the dispense path, a dynamic path adjustment can be created to keep the tip at a constant height above the part to within +/-0.0005" (13 microns). This effect is similar to using a Stand-Off Foot dispenser. Using a laser-style measuring system, this Virtual Stand-Off Foot dispensing can become non-contact, providing the accuracy of a Stand-Off Foot with the delicacy of non-contact dispensing.

    Use customized Webspace for access to backups of pattern files, user manuals, software updates, and more. A unique Internet Monitoring service is available for free with the new software. Track productivity and stay on top of maintenance and job scheduling. With the Personalized Webspace, New Precision Technology will take care of the machine from afar.

    Get the most out of your machine by re-tasking it after its work cycle is complete. Older machines can be rebuilt for a fraction of the original cost. Choose from three different rebuild plans to find the right one for you, and keep your machine running like new. Clearly defined rebuild checklists allow you to see the thoroughness of our plans. If your application has run its course, contact us for a quote on refitting your machine for a new task.

    New software eliminates undesirably harsh direction changes automatically, so that deceleration and acceleration takes place within machine limitations. Worry no longer about difficult sharp turns that stress the machine and limit rates of travel. Sharp Turn Optimization will determine the fastest transitions allowed.

    Arcs, dispense changes, and more have been updated for easier and more automated usability. Describe fillets and chamfers between program lines within a contour to smooth motion around corners. Rate changes are defined on a per segment basis with built-in ramping for maximum flexibility. Automated lead-in verification will keep lead-ins short and decrease cycle time.

    Financing has come a long way from the original upfront in full payment style. While the 50/50 plan has been standard for a while (50% before, 50% after), a recent connection with a local financing company allows us to accommodate even the tightest of budgets. Start the flow of income earlier and and see results faster.

    For the first time, a non-destructive measurement of a gasket is possible. Measurements can be taken before or after the material has been cured and is extremely accurate with sub-micron resolution. The tests are fast and use a non-contact, laser-based system for maximum quality. Once the scan is taken, height, width, and cross-sectional area information can be automatically extracted and logged.

There are two modes in which the scanning tool can be used: production mode and analysis mode. In production mode it becomes feasible to scan 100% each and every gasket for pass or fail status. Key dimensions and gasket integrity in many cases can be assessed even before the gasket is cured and with minimal time penalty. In analysis mode, cross-sectional area from single scans or 3D composite scans can be analyzed for key features, allowing production programs to be adjusted for optimal results.

    Plastic (and metal) injection molded parts often have parting lines that must fall within a specified height. The Automated Parting Line Detector finds, measures, and logs the parting line. With this information, the detector can act as a pass/fail monitor allowing downstream equipment to accept or reject parts or even inform polishing equipment to the degree of cleanup required for a given part.

    There are hundreds if not thousands of various compounds used for the purposes of gasket creation. One of the reasons for all of the variants hinges on the type of substrate or surface the gasket needs to attach to. Even the degree of attachment to the substrate is often manipulated: it is often necessary to have a gasket stick well enough to withstand normal use but yet unpeel from the substrate so that the part can be reprocessed in the event that an improper gasket is formed. And of course a gasket that sticks well on ABS simply may not stick adequately on glass filled nylon, let alone polypropylene.
To follow a theme seen throughout this site, it is important to evaluate your particular situation for suitability to purpose before launching into production!

    Our Machines are so versatile, we often equip our machines with an extra head to allow additional tasks to be performed, including soldering, stamping, and scanning devices. These applications are usually used in concert with another application.

    We are committed to supplying complete systems that are appropriate to your production situation. There are no hidden costs. No dispense valves to buy separately, no cables and no teach pendants. New Precision Technology is committed to helping our customers solve productivity issues for the long term. Often our equipment is in production within minutes of uncrating, allowing our clients to get on with the next issues on their dance cards.

    More than an OEM, New Precision Technology, Inc. strives to produce turn-key automation customized to suit your needs. Combining precision automation with versatile machine options, we can create a machine that performs customized tasks for a fraction of the cost of full customization. Our specialized design process and proprietary subsystems allow us to build unique, application-specific robots.

    Although our machines typically come pre-programmed as part of an overall turn-key system, we offer training sessions that cover programming for a broad range of applications and we share our experiences that minimize operator training, minimize part defects, and maximize your return on investment. We have a simple pattern programming scheme that does not require G-code knowledge or specialized training. We also have available tools such as a DXF file reader and a Gerber file reader that allow simplified importing, and a coating application assistant that dramatically reduces programming time for conformal coating and paint application programs.

    New Precision Technology is constantly researching new machine features to benefit our customers. Not only do we attempt to resolve existing production issues, we attempt to anticipate future issues and develop solutions that integrate seamlessly with minimal production impact. Fifth generation devices now cross-communicate, leveraging our production systems so that the whole is far greater than the sum of the parts.

Traditional dispensing tools are faced with process variations such as : temperature, part variation, fixture variation, and even operator variation (!) that require continual manual adjustments in pressure, speed, and even path location. These circumstances encourage the evolution of a unique plant position - knobologist. With our tools and processes, we eliminate the knobologist. The inclusion of these tools into a machine transforms a standard CNC platform into a stand-alone, high-precision, low-cycletime gasket applicator.

    Our Mission:

To create robotic manufacturing systems with exacting process control which will provide the best return on investment to our clients. As greater precision in automation yields reduced scrap rates and lower material usage, we will strive to develop sub-systems that ensure precision in the face of day-to-day production variability. Our seventeen years of experience with production automation and a policy of continuous innovation through research will be applied on behalf of our clients to ensure global competitiveness. We will continue to further develop applied automation intelligence which enables our systems to initiate corrective action without operator intervention.

    The very first thing we do at New Precision Technology is study the assembly situation. This includes not only the application, but also the level of integration, surrounding plant resources, and operator personnel. We utilize our cumulative experiences with many processes and make recommendations on materials, curing, packaging, and fixturing. We have likely handled many other types of problems similar to yours, and we can provide a feasibility assessment for the task you are proposing. Our goal at this stage is to gather enough information to make our base platform selection - benchtop, stand-alone, pallet-conveyor, in-line conveyor, batch-dial, or in-line dial.

    While we use the best materials possible (our bearing life calculations project 14 years MTBF), a manufacturing environment can be harsh on equipment. As a result, we offer a variety of plans to detect problems before they stop your production. We allow you to inspect, restore, and even reconfigure used machines, giving you a huge return on investment.

    Importing DXF files directly from a CAD environment provides a familiar editing tool for "drop-in" patterns. Pick and choose individual files entities and layers to best describe the paths for the new pattern program. Adjust the file to match the machine work area and substrate location in the fixture. Automatically generate the pattern program code to get production up and running as quickly as possible.

    A new feature to augment our laser scanning subsystem, our Instant Scan allows simple and easy scenario tests and verifications. By using a "virtual knife", the user can draw a line of interest on a model part from an imported CAD file. The system scans and displays the vitual cross-section of the line without any programming or part destruction. Traditionally, an object might be cross-sectioned and then examined with an optical comparator to verify component quality (for parting lines, for example) or dimensional height (gaskets). New Precision can now quickly obtain this information non-destructively with our non-contact laser measurement system at speeds reasonable for 100% in-line production inspection.

    UV cure gasket compounds have many production floor advantages that often have to be weighed carefully against their raw material costs. The UV cure process makes these materials immediately able to be handled and even boxed for shipment. Moisture cure RTVs can take hours or even days of rack time to cure. UV cure materials are process friendly - there are no solvents (VOCs) to flash off, moisture cure issues to deal with, or short pot life issues such as with epoxies. This means that short of exposing the dispense nozzle to sunlight (or UV from a cure system), your dispense tip should never cure. A hidden benefit of these materials is that some of them have minimal rheological variations due to temperature. Materials should always be checked for their performance throughout the expected temperature range that is found on the factory floor. If too much variation is found, it is often necessary to either heat or cool the material to achieve consistent dispense performance. Listed below are several sensors that help ensure consistent results and a slip coat application used in cases where the natural grip-tion of a rubber gasket is unacceptable and more slip-tion is needed!

    NPT has developed a unique method of optimizing motions for each dispensing situation. The process takes only a few minutes and can significantly trim part cycle time. By analyzing the current machine properties as configured for a particular application, we are able to determine the highest velocities and accelerations of which the system is capable. No longer is the user chained to a lowest-common-denominator default. In many cases this can dramatically increase throughput and yet the user can still rest assured that the equipment will operate consistently and without fail. Applications can now significantly benefit from lighter fixturing and dispense heads. This productivity enhancing feature comes free with our software package.

    New Precision Technology, Inc. re-introduces our LC line of equipment. Leveraging many of the built-in and ease-of-use features found in Windows XP, it is now possible to reduce much of the instructional and training overhead formerly associated with this type of automation. Our introduction includes two of what were our most popular models, the LC16-3 for conformal coating and the LC16-8 for gasket dispensing.

    NPT reintroduces our LC16-3 single head conformal coating machine. Now configured with efficient pattern generation software, setup and productivity have been radically enhanced. Load in gerber photoplot data or DXF information and it now becomes a matter of seconds to select desired coating areas and keep-away zones. With an adjustable fixture, EFD spray valve, and 2.5gal material tank, this is a complete system. Our LC line comes pre-programmed with several examples that act as tutorials when creating your own production patterns. If you require a system pre-programmed with your production parts or you require additional dispense heads, sensing systems, or axis controls, please consider our CP line of equipment.

New interfaces, simplified hardware, and more efficient controls enable us to offer this system for
$20,995.00

This system does not require any other equipment. You add the conformal coating, boards, and an operator and you will be coating boards with incredible efficiency.

This system is compatible with the following materials:
1) the Dow Corning 3-1753 series 100% solids moisture cure silicone coatings
2) the Shin Etsu 3421 and 3475TUV 100% solids moisture cure silicone coatings
3) the Dymax 984LVUF and 9-2557 UV cure 100% solids coatings

For other coatings, please inquire to determine suitability.
* Some coatings and facilities may require hooding or duct work to extract any fumes from the workspace. Please take this into consideration when siting equipment.

    Moisture cure RTV materials have certain strengths that make them an important player in the gasketing world. Unlike UV cure gasket compounds that cure virtually instantly upon exposure to UV, moisture cures can take several hours before they can be handled and they require a little more maintenance than UV cure materials as well - it's more difficult to keep humidity away from a moisture cure than it is to keep UV away from a UV cure! On the plus side, they do not have to be translucent like many UV cures (unless you have a dual UV/moisture cure like Loctite 5950) and this allows some unique properties - ones that enable silicones to survive in the engine compartment with high heat and oil contact. Also on the plus side: they tend to be far less costly than their UV cure counterparts!

Dispensing RTVs requires a few additional considerations:
1) A purge cup that can isolate the open dispense tip from moisture in the air
2) Larger material pumps with rams to get reasonable production rates
3) Material lines that present reasonable moisture barriers.

All of the usual gasketing tools have roles to play as well: vision, needle calibration, height measurement, and bead profile stations are all essential tools.

    As of this year, the main focus of our software development will be on our new Windows XP platform. We recommend that throughput critical applications consider upgrading to this platform as new features such as command stream time slicing, axis testing and tuning, and command optimizations have resulted in significant cycle time reduction. Many functions that formerly required operator interventions have been further automated, which has not only reduced the overhead associated with these functions but also has resulted in a reduced operator training requirement. Please do not hesitate to call 412-221-2206 with questions regarding your hardware.

    We at New Precision Technology, Inc. value your business and we take precautions to prevent the accidental release of client specific information collected on www.nptinc.com and www.newprecisiontech.com. The information you provide is used to help us keep you informed of the latest advances here at New Precision Technology, Inc. This information is kept on a separate server and is accessed only through a secure socket layer (SSL) encryption. We do not share this information with any person not an employee of New Precision Technology, Inc. nor with any other company.

New Precision Technology, Inc adheres to standard industry practices and employs virus protection software to attempt to curtail the dissemination of malicious agents such as viruses, trojans, and worms. All files exchanged through our web site are checked to the best of our abilities. However, no system is immune and New Precision Technology, Inc will not be liable for damages or interruptions associated with the actions of such malicious agents.

    Almost intrinsic to any assembly problem is how material flows into and out of the application zone.

Traditional batch mode systems are most cost effective in low production runs that require high change-over including many custom or adjustable pallets. While it is possible to convert batch mode systems to conveyor based systems, purpose-built conveyor systems are going to be optimal for throughput. Tools such as hoppers, magazines, matrix trays, vibratory bowls, and even multiple heads can help, but it is difficult to recapture productivity gains attributable to dial and conveyor systems with their typical one second dial index times and two second pallet transfer times. And of course all of the batch-mode optimizations can be for the most part brought to dial and conveyor applications.

Batch mode systems usually factor in a five to ten second part changeover time. While improvements can be made with 180 degree indexers and shuttles, the additional costs and the fact that these limit the integration of additional production steps make investment in these tools a limited proposition at best.

Dial mode systems are the most restrictive, limiting the size of the work area and fixturing must be general enough to accomodate all permutations, but these systems offer the highest throughput. Index times can be one second or less and usually no additional rotational-translational adjustments need to be made at the individual stations although often z-probing is still necessary. Dial systems can be restrictive on part size as well as each part must sit in a "pie-slice" of the dial.

Dial mode systems often (but not always!) require dedicated fixtures, welded steel frames and precision machine locations, significantly increasing their cost. However this cost becomes amortized over the higher production rates and so as long as annual production levels are there, dial systems provide the highest return on investment.

Conveyor based systems offer the best compromise: you dont get the throughput of a dial system but you get more flexibility. Flat belt conveyor systems are the most flexible, but usually require rotation-translation adjustment once the part gets into the work envelope. This can be done with push bars and shot pins, or with vision. Cam driven index belts can often be made to an accuracy that does not require further alignment, but now require the expense of dedicated fixtures.

    This system incorporates our ICP platform that can work over dials and conveyors. In this case, parts are presented to the machine via a conveyor and are fixtureless. The onboard vision system performs rotational/translational re-alignment using two openings in the part to properly align the program to the part. While this application is discussed elsewhere on this site, it is an excellent conveyor example. With a part to part cycle time of less than eight seconds, it illustrates the power of conveyor based part handling, the economy of fixtureless systems, and the power of vision systems to help adjust to parts on the fly.

    This system incorporates our ICP platform that can work over dials and conveyors. In this case, parts are presented to three separate systems using dedicated fixtures. Traditionally, dedicated fixturing is a hallmark of dial based designs. Often, however, parts can have sufficent similarity to each other - a form factor - that enables fixture costs to be dilluted across families of products.
The part to part dwell time is shortest with dial systems. This dwell can be as little as half a second or as much as two seconds depending on the overall size of the dial and the drive that causes the dial to index. Dials can be very heavy - 20 lbs for a simple, 180 degree index to several hundreds of pounds for a eight or more station dial made of steel - and the subsequent torque required for an index of minimal time can be staggering.
An additional consideration for dial systems can be on-load and off-load. In many cases an operator will place parts onto a dial, and depending on index rate, will also remove completed parts as the dial rotates a full turn. Faster cycles may require a separate operator simply to unload the dial. In advanced dial applications, robots will load dials and unload dials which forces issues of synchronization to come into play.
In this application, a gantry mold unload machine removes newly molded parts from an injection mold machine and places them on a small sychronization dial. These parts are then transferred to a main dial where several operations are done on the part before final evaluation and robotic removal occurs from the main dial. In this case, parts are scanned to see if they meet finish requirements. If they pass, they are sorted into left and right part lanes; otherewise, if they fail, they are placed into a reject lane.
Many operations can be performed The onboard vision system performs rotational/translational re-alignment using two openings in the part to properly align the program to the part. While this application is discussed elsewhere on this site, it is an excellent conveyor example. With a part to part cycle time of less than eight seconds, it illustrates the power of conveyor based part handling, the economy of fixtureless systems, and the power of vision systems to help adjust to parts on the fly.

    Gasket dispensing describes the extrusion of a viscous fluid that upon curing forms an elastomeric seal. After cure, when a mating surface is applied, the joined parts typically meet some requirement for a barrier against liquids or gasses. Commonly referred to as Form In Place gasketting (FIP), this process avoids the cumbersom aspects of handling and placing cut gaskets and affords the flexibility of many variations without having to inventory cut gaskets. As long as process issues such as part variations, material rheological variations, and operator induced variations can be addressed, FIP gasketting can be a production floor operation that adds value to the bottom line.

    This handy tool allows prospective customers to input the parameters of their application and receive recommended NPT machine setups. Multiple machine setups will be generated stressing either : overall machine cost, cost-per-part basis, or accuracy/reject rate. The tool is very user-friendly with tips for each input box and pictures to describe the desired parameter. If a parameter is unknown, it can be skipped and a default value will be used if available. Multiple projects can be saved for later viewings and can be updated at any time. Tool results will also display material consumption and show the rapid return-on-investment that NPT solutions offer.

This tool is available only to registerred users through the members tab on our web site. If you are not a member, simply register as a new member. While new members can enter all parameters, only verified registrants have web access to the final analysis. A simple phone call can verify your account and within seconds you will have access to the analysis.

    New Precision Technology announces true 3D planar correction! With the measurement of three points on a part, the CP System software can re-orient a part path for best-fit, further decreasing potential reject rates. Capable of being used with either tactile or laser based measurement systems, this easily incorporated feature brings added value to a system essential for quality gasket dispensing.

    Our newest calibration routines offer a simple, accurate calibration procedure to establish the relationship between all working heads - dispense, measurement, programming, and manipulation. By leveraging our needle calibration station, we can now calibrate tactile height sensors as well, establishing a perfect relationship between target substrates and dispense tips. Say good-bye forever to slips of paper and feeler gauges that were part of precision gasketing.

    Tactitle Height Sensing (THS) and laser height sensing have benefits that are often overlooked but bear enumeration:
1) NPT's Z-Gage Mode updates the Z height value for each coordinate automatically. Run your pattern in Z-Gage mode and you update your pattern to perfectly match the current substrate.
2) Single point, linear, and now planar correction provide fast and efficient means of matching the dispense path to the current substrate. With tolerancing set, it can cancel operations when things are out of tolerance or make minor corrections when things are within tolerance.
3) Single point test can be utilized as a go/no-go gauge test. Use it to verify the current substrate's state of assembly:
* Are threaded inserts installed?
* Are pawls properly mounted?
* Is the part even in the fixture?
* In a multi-part fixture, is there a part that is missing?

    New Precision Technology's System Software now includes a 3D graphic path view. Pattern paths can now be simulated on-screen, reducing the need for "going wet for test." The mode facilitates the creation of new pattern paths, showing the current programmed points and the current active head ("tip") location. This advance represents yet another incremental step in New Precision Technology's pursuit of easy-to-use interfaces married to advanced production techniques.

    Some applications demand high throughput that traditional batch mode machines like NPT's CP systems cannot supply. To address this need, NPT's ICP systems can be married to a rotary indexer so that concurrent operations can be done. Operator load/unload no longer adds to the overall cycle time as parts are loaded/unloaded on a separate "leaf" from the dispensing work area. The rotary indexer can be outfitted with a grid fixture to allow flexible palleting options, and each "leaf" can address a process - UV cure stations, inspection stations, and even other dispensing stations. Modular design allows the user to add leaf operations over time, as the production environment dictates.

More advanced processes can be incorporated as well: automated part load and unload, scanning, and even integration with automated molding machines is possible.

    The precise control possible with our advanced set of hardware and software tools makes it no longer necessary to aim for the top of the gasketting tolerance band. When a gasket specification is given, most applications are set up to dispense to the top of the requirement in gasket height so that the day to day process variations do not cause an undersized gasket to be produced. For example, if we have a 0.07" +/- 0.01" target, and I am able to dispense at 0.070" and instead I dispense at 0.080" in height, I am using up an additional 31% of material.

Add to this calculation the additional benefit of producing fewer non-conforming parts and it becomes plain that dispensing gaskets without good process control is a liability most companies can ill afford in this day and age.

    This calculates the volume of the gasket and the required dispense rate for the gasket. This also provides the gasket material cost and the number of gaskets a particular container could provide. Since all dispense setups have some variability, resulting numbers may not match actual measurements.

    This calculator estimates the amount and cost of material used in a conformal coat application. It also provides an estimate as to how much time is required to dispense the material.

    By estimating the resistances through common material setups, this tool provides a good "first guess" at how much pressure is required to move the material from the container through the tip.

PLEASE NOTE: THE ESTIMATES THIS CALCULATOR PRODUCES ARE ADJUSTED BY OBSERVED FACTORS OBTAINED THROUGH IN-HOUSE TESTING HERE AT NEW PRECISION TECHNOLOGY, INC. YOUR SPECIFIC CONFIGURATION AND RESULTS MAY VARY!

    This calculates an ideal FIP gasket height and width by taking into account the compression set of the material and the volume of space the gasket expands into when compressed. Several different gasket profiles and compression stop configurations are offered. These configurations also serve to illustrate key considerations when designing for re-seal-able gasket configurations.

Good FIP gasket design includes rounded contact points and reasonable clearance or esa large volume of space around the gasket.

    Masking of production parts is exclusive to no particular industry. Whether conformal coating, painting, plating, anodizing, chemical etching or bead blasting, a variety of part features often need to be protected from these manufacturing processes. UV curable masks offer a 100% solids, no VOC solution to what has traditionaly been a solvent intensive process. New Precision Technology's CP and ICP systems streamline the application of these materials on surfaces that can be complex 3D topographies. Here again our height measurement and absolute referencing systems eliminate the headaches of setup these applications have imposed in the past.

    New calculators that help with some basic and not so basic issues related to fluid and gasket compound dispensing. Use them to verify amount and cost of material, compression set and gasket design, conformal coat use, dispense rates, and pumping requirements for given rheologies. In one place you can find the key design tools you need for gasket and dispensing success.

    Enter in some information about the type of gasket application along with a few dimensions and this calculator will tell you what size of gasket will be necessary to do the job. It factors in compression set as well, so as long as you know the compression set of the gasket compound, you will get a good starting point for your gasket sizing. All situations are unique and so you may require something other than what is calculated. The classic disclaimer: IT IS LEFT TO THE PART DESIGNER TO DETERMINE SUITABILITY OF PURPOSE. These calculators simply are an attempt to draw attention to gasket design issues.

The tools are ultimately designed to be used in order: Gasket Height/Compression Set, Gasket Material Usage, and finally Pressure Drop/Material Flow.

Update 12/31/08 -
1) Gasket cost calculator fixed.
2) Aspect ratio for 1:2 (half-round gasket profile) is now calculated properly
3) Compression set is now factored in to both Minimum and Maximum range limits.

    The gasket material usage calculator can be used as a stand-alone tool or it can take the results of the previous tool - the Gasket Height Calculator - and help you figure out how much material you will use on a part, how much it will cost, how long it will take to dispense, and how many gaskets can be obtained from the desired material vessel. The height calculator results found in the previous tool can pre-populate most of the data in this calculator. This makes it terrific for "what-if" scenarios. In addition, the units can be separately specified for each entry. Enter a value in metric, change the units to imperial, and the appropriate conversion is applied.

The tools are ultimately designed to be used in order: Gasket Height/Compression Set, Gasket Material Usage, and finally Pressure Drop/Material Flow.

    How much conformal coat will you use on this project? Now there is a handy web-based tool to answer that exact question. Whether doing a raster path or a spiral fill, it is now possible to estimate material usage, dispense rate, and cost. Again, these calculators only provide best guess estimates, but we are updating these calculators constantly so they provide the most precise estimates.

This is a stand-alone tool. Enter your board size, spray path width, cost per container, purchase container, and desired thickness and you will receive an estimate of time per part, number of boards per container, and cost per part. This tool currently assumes 100% solids coatings such as moisture cure silicones or UV cure coatings.

    This tool attempts to estimate the pressure required to meet a given dispense rate - a rate that is derived from the results of the previous tools. It estimates the results based on common configurations here at New Precision Technology, and so your results may vary! Even though we are in the early development stages of this tool, we are releasing it to the public because it provides essential information and in many of our test cases the results have been realistically accurate. The crucial element of this is a lookup table based on our own in-house test results with various materials over the years. As we populate this lookup table with additional flow information, we expect it to become even more accurate over time.

The tools are ultimately designed to be used in order: Gasket Height/Compression Set, Gasket Material Usage, and finally Pressure Drop/Material Flow.

    Cut manufacturing costs by 15 to 30% over conventional robotic systems through the use of advanced process controls.

    Fuel cells can present interesting challenges when it comes to gasketing and sealing the spaces between plates. Stackup problems can become quite pronounced when multiplied by the number of plates in the stack. Well-defined specifications for fuel cells can simplify the process requirements.

Precision requirements along with tolerance requirements go up as gasket sizes go down. As gasket sizes go down, it becomes even more critical to have the right tools on hand so that reject rates do not go up. Three point planar skew adjust, needle tip calibration, and the capability of dealing dynamically with valve on-off lead-lag play ever more important roles as bead sizes go down.

Confirmation of dispense quality becomes a key issue as well. Our laser scan option can help confirm gasket contours meet design specification without any additional handling.

A final consideration is the curing of FIP gaskets. With small fuel cell plates, it becomes quite reasonable to cure these gaskets right on the dispenser. This eliminates handling wet parts and allows for rapid stack assembly. Curing plates on the dispenser with an onboard UV oven enables precise curing profiles to be administered.

For high volume production, consider an ICP configuration mated with a rotary dial. It then becomes possible to integrate magazines, part handling, and UV cure modules to allow for cost-effective full automation.

    New Precision Technology has developed in-house a new standoff foot dispensing technique designed to deal with part height variation as a production issue. While the basic standoff foot technique has been with us for quite some time for precision dot dispensing, it is normally considered impossible to dispense a closed shape (circle, square, etc) using this method as the foot will run through the gasket at some point. To address this, we rotate the part, which prevents potentially messy dispense valves from being complicated with rotational hardware. This technique lends itself to precision gasket formation for fuel cells, LCD screens, display terminals, and any flat structures requiring precision gaskets or adhesive seals.

    Form in place shaped gaskets can provide some surprising benefits to traditional circular gaskets. The traditional shape of an FIP gasket is the result of a gasket compound flowing out of a round tube. Rheology aside, the shape is some form of circular arc, however as the tip skims closer to the substrate, the tip starts to carve a shape into the top of the gasket. The result of this action is typically a flattened rectangular shape with rounded vertical walls. This result is due to three factors: the proximity of the tip to the substrate, the flow rate of the compound as it comes out of the dispense tip, and the rate of travel of the tip over the substrate. When the flow rate is high enough, the travel rate is slow enough, or the gap to the substrate is small enough, the substrate in effect becomes the final wall in a pressure vessel.

With this process, it is possible to create shapes in the side of a dispense tip and extrude material out of the side of the needle. And there is no limit to the possibilities. For example, ridges on the top of the gasket will reduce the amount of compressive force required for engagement between surfaces. This can give some of the advantages of foamed gaskets without going to the expense of the foam generating hardware.

    The FIP Gasket Height Calculator attempts to calculate a reasonable height range for a standard FIP gasket.

Height-to-Width Ratio is the ratio of the gasket being dispensed. For self-leveling materials, 1:2 is usually a sufficient estimation.

Implementation Style describes the way the gasket is used. If the gasket is in a channel, the channel width field appears.

Spacing Height is the height of the gasket during compression.

Compression Set is the compression set of the gasket material. This should be provided with the material or it can be tested with the proper equipment.

Channel Width defines the width of a channel the gasket may be dispensed into. It only appears when the Implementation Style is appropriate.


For the minimum height, the following equations are used:

Minimum Height = (Spacing Height) / (1 - Compression Set%)
Minimum Width = (Minimum Height) / (Height-To-Width Ratio)


The maximum height is calculated by matching the gasket area to the compressed area and solving for the gasket height. Each aspect ratio has a different area calculation, but the width calculation is relatively the same.

Aspect Ratio 1:1
Maximum Height = SQR( 4 * (Spacing Height) ^ 2 * (Height-To-Width Ratio) / PI)

Aspect Ratio 1:2
Maximum Height = SQR( (Spacing Height) ^ 2 * (Height-To-Width Ratio) / PI)

Aspect Ratio 1:4
Maximum Height = SQR( (Spacing Height) ^ 2 * (Height-To-Width Ratio) / (2.7956) )

Maximum Width = (Maximum Height) / (Height-To-Width Ratio)


Finally, if the Maximum Width is larger than the Channel Width, the Maximum Width and Height are recalculated:

Maximum Width = (Channel Width)
Maximum Height = (Channel Width) * (Height-To-Width Ratio)


If the Maximum Width is less than the Minimum Width, or the Minimum Width is greater than the Channel Width, an error is displayed.

    Fixtures are a key part of the consistent production process. Both precision and accuracy are required; precision to ensure repeatable, part to part consistency, and accuracy to simplify setup and reduce the amount of training required to set up jobs consistently.
Good fixtures have the folowing characteristics:
1) Ample finger clearance and allow operators or other material handling elements to quickly load and unload parts.
2) Can be easily cleaned up if there is a need to do so.
3) Can be rapidly interchanged with other fixtures without concern for updating offsets or making height adjustments
4) Are poka yoke'd so that a production level operator cannot err when changing fixtures.

New Precision Technology has an internal design rules list of seventeen elements that must be considered for any new fixture design. These rules are a compendium that is a result of (ironically) seventeen years of fixture desing.

    For short production runs, adjustable fixtures can be quite beneficial. However, to be most effective , they do require that the products to which they are applied are of a type. They are most effective when dealing with various sizes of a similar object. For example rectangular circuit boards, or enclosures of various sizes.

Linear rail adjustable fixtures are excellent choices for short production runs of rectangular circuit boards or other thin, flat, and rectangular products. Usually they are set up to have a fixed bottom left corner, a back adjustable rail, and then stops to constrain left and right motion. Optional steel scales on all four sides makes resetting the fixture back to pre-existing pattern programs a simple task.

Grid fixtures represent the most flexible alternative in the pantheon of fixtures. Our grid fixtures are an array of 8-32 tapped holes on one inch centers. Each grid fixture comes with a kit of standoffs and a set of parallel rails that are slotted for maximum flexibility. The pitfall of this type of fixture is that it is difficult to change the fixture back to a pre-existing configuration once it has been changed. Conversely, the grid fixture is relatively inexpensive because they are made in quantity, all fixtures have machine bushings for mounting, and it now becomes reasonable to have multiples of these to deal with odd components. When an application is known to be at an end, it becomes reasonable to strip the adjustable fixture and put it to use for the next unique application that comes along.

    The FIP Gasket Material Calculator calculates the volume of material used in a gasket to better aid dispense rates and material costs.

Height-to-Width Ratio is the ratio of the gasket being dispensed. For self-leveling materials, 1:2 is usually a sufficient estimation.

Gasket Height Max describes the tallest acceptable gasket. This can be calculated using the Gasket Height Calculator.

Gasket Height Min describes the shortest acceptable gasket. This can be calculated using the Gasket Height Calculator.

Gasket Length is the length of the gasket. If several small gaskets are used, add the lengths of each section together for this value.

Container describes the kind of container used to dispense this material. For this calculation, only the volume of the container is used.

Container Cost is the cost of a container of material. This is used to estimate the cost of the material.

Desired Dispense Time is an estimated amount of time required to dispense the total length of gasket. This estimation should not include any overhead associated with machine motion. It should be based solely on the required time to dispense the requested volume of material.


The calculations for the volume is straight forward. The cross-sectional area of the dispense is calculated and multiplied by the length.

The Mean Volume calculation uses the average of the Min Height and Max Height to calculate the cross-sectional area.

Using the container size and container cost, a price per volume is calculated. This value is multiplied by the volume to get a cost per gasket.


Using the Mean Volume, a Gaskets Per Container is estimated by dividing the gaskets by the container volume.

The Dispense Rate is calculated by dividing the Mean Volume by the Desired Dispense Rate.

    The Pressure Drop Calculator estimates the amount of pressure required to dispense a material through a given material dispense system.

Several assumptions are used that may alter the estimation from the actual results. The calculations assume the following about the material and its system:

• Newtonian Fluid


• Non-compressible Fluid


• No Gravity


• No Friction Containers


• Laminar Flow

8 ρ Q² L
Δp = --------- * λ * ---
π² D⁴ D

    Dedicated fixtures are designed to meet the needs of a particular production part. They can be made quite accurately and their only limitation in accuracy is the production variation inherent in the part itself. It is not uncommon for fixtures to be made with 0.001" accuracy.
A variety of techniques can be employed with dedicated fixtures: they can be molded to fit the production part, they can employ vacuum at various points, they can include clamp bars (De-Staco and other systems, beds of pins can be arrayed to conform to the bottom of a part, etc.

    Many of our customers work with production parts that can have flat or flattish bottoms. Fuel cell plates, curved display glass, ceramic plates, etc. These tend to be brittle forms that cannot be flattened with something like a vacuum fixture - although often a three ball array fixture will employ a vacuum cup in its center.

The three ball array works well with our planar skew correct software. The three balls establish an arbitrary dispensing plane for the part and our software then automatically matches the pattern program to the part. The net result on a rigid part is a perfect plane-to-plane match. The only way to be more precise would be to rescan each individual point, a technique that while accurate is quite time consuming.

This type of fixture lends itself nicely to those types of applications that benefit from a template based periphery locating system. The operator places a template used to locate the part, places the part, turns on the vacuum, and then removes the template. Alternatively we have, in the past, mounted the vacuum and three-ball array on a riser platform which would allow the template to be clear of the part during dispensing and subsequent part offload.

As always, if you have any questions, please do not hesitate to call.

    Many objects going through manufacturing processes are inherently flat and rectangular. And yet these two characteristics are becoming less necessary as pre-requisites in today's factory. Consider a circuit board. It meets the "flat and rectangular" requirement to a respectable degree. And for the last two or even three decades the conveyor handling of circuit boards has been commonplace. Today, with sophisticated vision systems (sophisticated in that complex vision algorithms are given "handles" that render them far less complicated to implement), height measurement systems, and other tools, it becomes reasonable to pass parts by a robot via flat-belt conveyor so that adhesives, greases, or gaskets can be applied no matter the orientation of the part, short of the part being upside down.

With any conveyor application some consideration needs to be given to handshaking. Typically in a conveyor system a part passes by or through a robotic work zone. Preceding process equipment is considered the "upstream" hardware and the equipment that follows a given zone is considered the "downstream" hardware. A very basic communications protocol was developed by the Surface Mount Equipment Manufacturers Association (SMEMA). It specifies a downstream output (Board Available) and a downstream input (Machine ready). The upstream output was the inverse of the downstream. Now, machine-to-machine and machine-to-factory communication protocols are highly refined, efficient systems that fully leverage factory floor information technology.

    We have rounded out our pressure drop calculator to be a bit more general purpose. The previous version of the calculator handled quite a few "behind-the-scenes" conditions unique to our equipment - predefined hose lengths, connectors, regulators, etc. This new version makes those calculations more transparent and allows the end user to configure more possibilities and analyze many more arrangements.

    With a theta mounted on the Z axis, it becomes possible to accurately dispense gaskets along the vertical walls of objects. In this example we have machined sockets which require a seal at the entry point. By itself this is not a difficult concept. The difficulty in doing this kind of thing in production lies with the issue of tip calibration. Using a unique calibration process that definitively locates the dispense tip no matter the tip angle or length of arm from center of rotation, New Precision Technology has simplified this technique, making it a production-friendly process.

In this application we applied a gasket to the inside of the socket as well as to the outside face. The outside face was not necessary, but dispensing the gasket on this face was more observable.

    Sometimes capturing minor height variations relative to standard surface roughness can be difficult. If your standard surface roughness is 1/2 a micron and the profile is another 1/2 micron, it can be difficult to see the forest for the trees. Taking a 3D scan of a surface enables you to see patterns that would otherwise be missed. While it may take significantly more time to do a 3D scan, it is certainly worthwhile if the feature locations are unkown or can vary. The photos illustrate this vividly.
Some assessment of conductive ink print quality can be made between the two solar cells tested. In the lesser quality cell there is much more variability in the printing of the bars.
Also shown is a black ink print on brushed aluminum. A simple 2D scan removes the context and it becomes slightly more difficult to determine the region of interest. Placed within a 3D context, the region of interest becomes more apparent.

    A new interface board adds scaleable capability to the entire line of New Precision Technology, Inc's robotic platforms. This addition now enables us to offer microstepping systems in either the traditional open loop format or in closed loop encoder feedback servo format. This board also includes a built-in CANbus interface, isolated IO, and stackable expansion.
The design allows the mounting of the axis drives directly to the board, saving valuable space, reducing wiring requirements, and ultimately giving New Precision Technology, Inc. a hedge against rising material costs.

    Printed Circuit Boards (PCBs) are typically fabricated from Gerber data (aka: EIA RS-274) and as a result are often available for use in other manufacturing processes. DXF data can be made available for many other application types or even readily created on the fly. Both of these data sources can be read by our Gerber Reader software package and used to quickly and efficiently generate pattern programs without causing machine down time.

The Gerber or DXF data here is used to provide a visual frame of reference for the user. The user first defines exclusion or "no-fly" zones by drawing boxes around features to be avoided: connectors, potentiometers, test jack points, headers, etc. Once complete, a "coverage area" is defined and the program automatically generates an efficient pattern program based on user-configurable head data. Up to four heads can be defined with height, clearance, spray width, theta angle, and other characteristics.

Smart analysis routines in the program generator highlight "danger" zones - spray coverage too close to connectors, for example. The package even includes an option to "correct all errors" - a feature that causes the program to do "best-fit" analysis and realign spray and dispense paths for best results.

    Leveraging the advantages of pc platforms, New Precision Technology has incorporated a USB video interface into our DispenseLink software. This now enables us to offer video from directly within the DispenseLink interface. This video feed overlays an adaptive crosshair atop the image and also offers up to 8x digital magnification.
The camera is considered one of four possible heads on the platform, complete with its own offsets and built in calibration to relate the crosshair center with the dispense tip and other heads. This makes the camera an exquisite tool to update CAD coordinates with part as-molded variations.
Another interesting use of the camera is as a tip calibrator for angled tips that are theta rotated. The 8x magnification makes +/-0.001" repeatable tip location a production floor level reality. In one case, six different operators calibrated dispense tips using this system with no discernable variation in gasket quality.

    UV cure materials have many critical production floor advantages, but many UV cure materials are skin sensitizers and present contact dermatitus issues. In low cycle time, high volume applications, the newly formed gasket or dispensed conformal coat is passed on automatically to a UV cure lamp by either conveyor or index table. In low volume applications this additional automation can be cost prohibitive, causing many to opt for operator load and unload of uncured parts.

At New Precision Technology we have an alternative for low volume production: on-board uv cure. With this process, a gasket or coating is dispensed and then the part is driven to the back of the dispenser where a UV lamp exposes the material and the material then solidifies. As a result, the operator is not exposed to uncured material through part handling. As there are no handling steps between dispense and cure, there is no opportunity for accidental deformation due to handling. Gasket slumping is controlled as the interval between dispense and cure is strictly defined.

While this is not a new process for us - we have systems with on-board UV cure that have been in the field for more than ten years - our new graphical-user-interface tightly integrates a variety of differing UV manufacturer's systems with our controls. This tight integration allows better diagnostics, improved shutter control, and in many cases, more precise exposure control.

    Our height measurement capability has been recently augmented with the addition of the Keyence GT2 tactile height sensor. When coupled with New Precision Technology's advanced calibration procedure, the sensor perfectly follows the motion of the Z axis of a dispenser. Jogging the machine 0.0001" and having the probe follow with excellent synchronisity is causing us to re-evaluate whether the 0.002" accuracy we advertise in Z is a bit too conservative!
The new probe also has an excellent bearing for the contact rod and as a result there is no ambiguity as to what point is actually being measured. In the past with loose fitting LVDT rods, measurement of points with small areas or slopes in Z (such as circular cutouts in the XZ or YZ planes) was cause for concern as the probe could slip in the XY plane. With the new GT2, the probe is not prone to this slippage and the measurements are more accurate.
Finally the data rate out of the new probe is higher than in the past, allowing for better measurement rates and even better accuracy as more stability samples can be collected in less time.

    Many devices can be added to the base platform of a CP16 dispenser to increase its utility. Options such as

* Purge cups
* Material detection stations
* Part inspection mezzanines
* UV Cure station mezzanines
* Magnetizers to magnetize blank magnets
* Hot Melt glue heads to apply adhesive to the bottom of parts
* Activator applicators to apply activators to the bottom of parts
* Vibratory bowls
* Bar code reader stations to identify parts, pallets, or tracking IDs

Typically after dispensing the part travels to the back of the machine where these value-added operations take place, after which the pallet shuttles forward so that the operator can remove the completed (and cured in the case of the on board UV Cure mezzanine) part and place a new part on the pallet.

These operations are serial in nature: first the gasket is placed for example and then afterwords the product goes through the base-mounted accessory. If takes 20 seconds to dispense the gasket and 10 seconds to cure, the total operation time is 30 seconds. The total cycle time should include operator changeout and coarsely a 10 second interval is assigned to this. Therefore the total operation time is 60 seconds. Contrast this with an ICP based system where the part is on an index table and there the cycle time in this application is 21 seconds with one second given over (roughly) to part index time. In situations where the volumes are moderate or there are other mitigating circumstances, the CP system with on board UV cure is a very cost effective option.

    Although our first dual Y axis machine was sold in 1998, the recent economy has helped to increase the urgency for greater productivity gains with manageable cost structures! And so we have decided to put together an illustrative demonstration of the advantages of a dual Y system.

With a typical batch mode system, all operations are serial in nature: the operator loads a part, the operator presses run, the machine does its function and stops, the operator unloads the part and the cycle starts over again. The load and unload sequence is something that we conservatively estimate at a 10 second time cost. As the cycle time drops below about 1.5 minutes, the consequence of this 10 second layover becomes more significant. If you have a 10 second cycle time and a 10 second change over time, fully half of your plant productivity is given to getting parts on and off of the machine!

At a certain point (also around the 10 second mark) it gets to be more difficult for a line operator to keep up with the machine and then something with automated material handling, such as our ICP line, should be considered. Some parts are simply too awkward to be able to load and unload quickly and safely.

One of the interesting elements of New Precision Technology's take on this type of configuration is our "queued" over-ride. The operator loads the parts and as soon as they are loaded, they can press the RUN button and the machine will begin a new cycle right after it finishes the current cycle.

NOTE! With these systems relying so heavily on operator loading consistency, some consideration should be given to validating the part load by way of sensing. Often, New Precision Technology will employ vacuum sensing, prox sensing, ultrasonic sensing, or tactile sensing where appropriate. A very effective example of vacuum sensing can be seen in the hot melt video found through the supplied link. In this example, the presence of a plastic sheet is sensed both when applied and when removed. In this double test method we can actually use the vacuum sense as a run cycle signal, allowing for a seven second cycle time!

    White papers, articles, and other resources on a variety of topics such as Return On Investment, Process Control, and Dispensing Techniques and Considerations.

    Under our TOOLS AND RESOURCES tab, we now have additional resources which will consist of various links to industry web sites and various white papers we have issued. For the moment, the two papers we have incorporated into the site cover

1) Return-on-investment issues (ROI determination for a given project) and
2) Process control through height measurement and needle tip calibration.

We are planning several additional articles, and as they are added, we will mention them in our newsletters.

    Dispensing fluids (almost regardless of viscosity) presents unique challenges that can frustrate successful implementation in a factory floor setting. Unlike many other automation tasks, there are numerous process variables to consider. But unlike in the past, there are today tools and techniques that can help manage these variables, often in completely automated ways. With advanced software these tools can work together in a sensor/process fusion that can greatly increase part yield. This series of articles intends to look at some of these issues, their possible solutions, and the impact on the bottom line.
This first article deals with height measurement and dispense tip location and the synergy between the two sensing systems. This is a sensor mashup where the effectiveness of the mashup is much more than the sum of the individual sensor benefits.

    With the advent of computers, complex manufacturing machines and automatic assembly equipment, the urge to automate all aspects of manufacturing strikes many engineers and engineering managers. However, automation, with its high capital start up costs, is often a difficult sell to management worried about the short term bottom line. A rapid return on investment (ROI) can quiet management fears and confirm the validity of the decision to automate. But how does the overworked line engineer (solving problems on the fly just to keep the present equipment running) or the busy manager (already bogged down with paperwork chores) find the time and energy to analyze his operation and compute capital equipment depreciation, material savings, labor costs and all the other details needed for a complete ROI assessment?

    Industry Links. Essential web sites for gasket compounds, soldering materials, conformal coating materials, cyano-acrylates, epoxies, and other materials. Look here for safety links (manufacturers of safety equipment as well as a link to OSHA) and other industry resources.

    Helpful links for all engineers!

    Assembly Magazine publishes an article on gasketing design rules by New Precision Technology's founder, Axel VanBriesen. The editors chose not to include the illustrations which are attached here in the image file. The key point here is that it is possible to quickly and efficiently design and confirm the design of re-usable sealing interfaces.

    Adhesion promotion, resistance, and control is a crucial element of successful bonding, sealing, and gasketing operations. There are occasions where an application needs the most aggressive bond possible and other applications that require less aggressive techniques. Ultimately, the bond strength only needs to be as strong as the weakest bonded surface.
There are many methods of adhesion promotion and all of them have their strengths and weaknesses:
1) Flame treatment
2) Corona or plasma treatment
3) Solvent etch treatment
4) UV "bedding" materials
5) Soda or Sandblast etc
6) Adhesion promotion chemistries
Over the last two decades of dealing with adhesive, sealant, and gasket applications, New Precision Technology has implemented all of these processes and more.

    As a service to the MSC club members and friends, this page provides linkes to pages on machined parts to be had for homebrew sailboats. These parts are all made here in Pittsburgh, PA, and we attempt to be cost competitive!

You will find various pages here that describe rudder hardware, block hardware, and any other metal components that will help trick out your ride!

Some of my friends ask "What on earth are you doing?!" My response is that being involved is a worthwhile endeavor. Building these boats is an activity which can bring families and friends together. Cost for the activity at the low end $100 for a boat that can provide all the lessons a more expensive craft can, is far more stable than most, and can be built with basic tools at home.

    The main advantage to this design is that there is almost nothing to align. Everything gets mounted to a common plate and that plate is bolted on to the transom. You supply the transom (presumably with boat), four bolts 0.25 inch od (1/4-20), and a rudder made of 1/2 inch thick (really closer to 15/32) plywood.

This kit includes:

1) Top gudgeon with bronze flange bushing PTFE filled (lubricant)
2) Bottom gudgeon with bronze flange bushing PTFE filled (lubricant)
3) Base plate with 4.25 inch holes to simplify mounting to transom (gudgeons and retaining tab are mounted to this plate)
4) Top pintle with short ss pin
5) Bottom pintle with long ss pin
6) SS spring steel retaining tab
7) 2 ss bolts 8-32 1.25 inch long with washers and nylon insert lock nut for rudder.
8) 2 ss bolts 8-32 1 inch long with washers and nylon insert lock nut for rudder.
9) 2 ss 8-32 BHC screws 3/16 inch long to retain the spring clip to the base plate.
10) 4 ss 8-32 FHC screws 5/8 inch long to secure the gudgeons to the base plate.

To reign in costs we are not at this point providing anodizing, but if interest kicks in, we will give it consideration.

The kit is meant for a rudder made of 15/32nds (1/2 inch) plywood. We have found the plywood thickness to be highly variable and some sanding of the rudder might be required to get a smooth fit.

Total rudder kit price is $25 per set plus shipping. Active MSC members receive a 20% discount.
All parts are fabricated right here in Pittsburgh for minimal carbon footprint!!! Eat local!

    An initial trail for very low cost blocks to be used in a variety of locations. The key advantage here seems to be that as sheave diameters go up, costs increase substantially. These blocks with 3" sheaves for up to 3/8" sheets are only $7 each.

Possible future enhancements include directional frictional loading, and a variety of mounting options.

    Please note - all machine specific data is located in the members area. Customers with equipment can access this area for:
1) illustrated parts breakdown manuals
2) Electrical and electronics documentation
3) Recommended spares list (part of the users manual)
4) Users manual!
Certain custom applications will also have customer specific cloud storage space for machine drawings and programming examples.

If you have a registered machine, you have web access to the users area.
Note: If you have opted for real time web monitoring of your equipment, this is also accessed through the members area!

    Safety on the manufacturing floor is always a critical consideration but for some reason, it is not an uncommon practice to market split axis machines with work envelopes larger than the footprint of the machine. This means that the moving pallet which is typically on the Y axis moves past the front (and rear) edge of the machine. Operators are then potentially in the path of the pallet as it moves back and forth.
In any reasonable machine design, no motion component should project beyond the footprint of the machine. A machine with a 500mm travel in the Y axis should have a base 1000mm from front to back at least. Of course the pallet can be design limited to not extend beyond the footprint, but this then shrinks the dispensable area in the Y and so purchasing a machine that doesn't have twice the footprint as the travel in the Y is not an effective use of funds!
In short, for any split axis design such as our CP16, CP2416, and our newly designed CP2420, the Y axis travel should be no more than half of the Y machine base footprint.

    We are now announcing our larger base platform! While our standard CP16 platform has a depth of 31 inches, allowing a safe Y travel of 15 1/2 inches and a max work area in Y of 15 1/2 inches, our new platform is 39 1/2", giving a safe Y travel and work envelope in Y of 19.6" or 498mm. If the application has stations on Y, an option that limits maximum pallet size, Y axis travel can be configured for 28.5" or 723mm.
This platform uses our standard X configurations. As a result, X standard travels of 16" and 24" are available off the shelf. We can readily supply X travels of up to 32" on our CP platforms.
Extended Y axis travel is most helpful in those applications that benefit from on-board UV cure systems. These on-board systems are efficient, cost effective, and safe as the operator never handles uncured product. Depending on application cure demands, both Uvexs and Dymax supply UV cure systems that integrate well with CP platforms.

General Components

    Originally developed back in 2007, our theta axis calibration system is rather unique. The difficulty with head mounted dispense tips that rotate is that the tip really needs to be compensated during all degrees of rotation. A fixed dispense tip is relatively easy to calibrate - check X, Y, and Z offsets and tip diameter and you can readily generate a real world offset to the dispense tip. If the tip rotates, these offsets no longer apply.
In order to calibrate a tip with a bend you also need to consider the distance from the center of rotation to the orifice (what we call the arm). During rotation a circle is circumscribed by the arm and from that you can derive the center of rotation. Effectively the tip has its own coordinate frame that gets applied to the pattern during run-time.
In the past, a tip with a bend might have been manually rotated into position once the head theta was in the home position. That is no longer necessary and because of our camera-based tip calibration for theta, the results are astoundingly consistent.
Equipped with information on the arm and a calibrated center of rotation, it is now possible to do some things that are quite interesting. For example, as long as the tip does not physically interfere with the part (the bend accomplishes this typically) it becomes possible to dispense on an inside radius that is smaller than the arm length!
Perhaps that last does not sound remarkable, but as with all of our applications, we attempt to use CAD data rather than modifying the dispense path to accommodate the configuration of the dispense equipment.

    Our systems capitalize on the advantages provided by a dedicated motion control board. This board brings the following features and benefits to our equipment:
Features
1) Constant velocity contouring (CVC) across all axis.
2) A variety of interfaces including USB, Ethernet, Hardwire, RS232, PC/104, and PCI.
3) A uniform driver library across all board variants.
4) Compatibility with steppers, servos, and encoders
5) 32 bit RISC processor
Benefits
1) CVC is crucial for fluid dispensing in time/pressure applications to control.
2) Interface flexibility enables the best selection depending on the application and level of integration desired.
3) Uniform libraries enable us to concentrate on our core competency of application problem solving!
4) All of our CE marked equipment is servo based to help meet European safety requirements
5) This advanced processor handles position control so the computer controller doesn't have to!

    Any discussion of adhesion promotion for plastics is not complete without considering surface energy. Surface energy, in simple terms, indicates the tendency of materials to "bead" on a surface. The Wikipedia explanation is long and complex (and a link is given below), but basically the greater the surface energy, the more likely any given liquid is to spread over the surface. The lower the surface energy, the more likely any given liquid will bead up on the surface. Substances like wax have a low surface energy and that is why when we wax our cars, water beads on it afterwards. Alternatively dish soaps have surfactants that decrease the surface energy of the liquids they are mixed with and this allows the detergent to "wet-out" and spread over the dishware!
While there are excellent pieces of lab equipment on the market to measure surface energy directly, one inexpensive alternative is the dyne pen. Dyne pens are available in sets and commonly available in a range of 30 to 60 with special pens outside of this range also available.
The issue with dyne pens is that the test is very subjective and it is typical to have measurements of +/- 3 or more.

    Corona treatment is a process by which plastic surfaces are modified to increase their surface energy. This increases a surfaces' "wettability" and allows adhesives and sealants to obtain a greater bond strength.

This process produces a large amount of electro-magnetic interference (EMI). In the process of going through 3rd party CE testing for emissions and immunity, we have learned how to mitigate the effects of EMI in our systems. As a result, we can implement this process with a high degree of reliability. Other electronic systems may be influenced adversely by the effects of EMI. This includes things such as pace-makers and other health electronics related equipment. Even though we are manipulating a transducer that can be hand-held, we recommend keeping all other electronic devices at least three feet away from the transducer.

This device also creates a small amount of ozone. It is recommended that this system be used in an area with adequate ventilation.

    Sandblasting and Sodablasting are proving to be remarkably effective adhesion promotion tools. In one case we have achieved a four fold improvement in the adhesion of Dow Corning silicone to acrylic.

Cleanup from sandblasting is a consideration. The grit can accumulate on the part and so brushing, air blast, or vacuuming is necessary to ensure grit removal. Our ICP unit is a good choice for this type of application. The motion can be isolated from the blasting area and so the grit can be contained. Incorporation of a dial platform further constrains the blast area and ensures the operator never needs to reach into the work zone.

The current videos and photos are of our initial trial runs and do not have full enclosures!

    Patent #'s 10525627 and 10220559

Hollow gaskets can be engineered for selectable compression characteristics. Unlike homogenous foamed gaskets which can be thought of as a spring - gradually applying more force as the seal is compressed - extruded seals can provide initial stiffness and then a sudden decrease in required compressing force.
As a result, it can take surprisingly little force to cause deflection in the seal. This allows a high degree of compliancy in the seal, making this technique ideal for sheet metal sealing applications or allowing sealing against very irregular surfaces.
Alternatively the seal can be designed with a cross section that looks like the letter "B" on its side where the center leg does not get attached to the the bottom. Now, as this seal is compressed, the compressive force is very light initially, but when the center leg bottoms out the force to compress rapidly increases.

    Patent #'s 10525627 and 10220559
Our shaped gasket dispensing process, which we developed in 2006, has opened a wealth of new possibilities in manufacturing, allowing us to re-write the book on traditional gasket dispensing. Hollow and filled gaskets offer the following advantages:
1) Hollow gaskets can save 25-75% of material costs
2) Hollow gaskets provide their own compression "zones"
a) No additional provision needs to be made for elastomer squeeze-out
b) Issues with channel wall shear are reduced or eliminated
c) Compressive forces are greatly reduced
d) Compressive forces can be made to toggle the gasket profile
i) The forces can actually diminish with additional compression.
e) Compression set seems to be less pronounced in many cases
3) Materials requiring UV cure are now more efficiently cured

    Patent #'s 10525627 and 10220559

This variation of hollow gasket dispensing offers a direct replacement for traditional solid gasket dispensing.
Hollow gaskets in this category offer:
1) Greatly reduced material usage
2) The effective force of compression is far less than it would be for an equivalent solid gasket.
3) For many RTVs and UV cure silicones, the cure time is reduced and intensity requirements are also reduced.

Small and large gaskets were done in Novagard 400-150, an oxime moisture cure RTV.

    Patent #'s 10525627 and 10220559

We were recently presented with a new (to us) material to test with our hollow gasket process: Tangent Industries 60102 material. This material has some interesting characteristics: low or almost no tack after cure, soft, and relatively low UV exposure energy requirements.

One other characteristic was interesting however: the viscosity relative to silicones (which had occupied the bulk of our previous testing) was much, much lower. The net result of addressing this characteristic has given us process controls far more advanced than our previous attempts and have had follow-on implications for previously tested materials.

Image number one shows the cut-out section of a gasket with approximately a 0.15inch diameter and a hollow that accepts a 0.090 inch pin gauge without deforming (see image two). A 0.107 pin gauge actually still slides easily into the gasket center but it also raises the gasket and so clearly the hollow is larger than the 0.090 height might imply. However, calculating surface areas conservatively, the hollow provides a 34% reduction in material usage.

When designing applications for hollow gaskets, a solid "O" ring interpretation works quite well. Traditional solid FIP gaskets always require an escape zone - somewhere for the gasket to go to when it is under compression. With the hollow gasket, the hollow becomes the escape zone. For a properly designed application where the deformation does not exceed the hollow, no escape zone is necessary.

While extremely crude, images three and four attempt to show the reduction in effective durometer of a gasket due to the hollow. Image three shows the very rough measurement of a solid gasket and image four shows a gasket with the exact same height but with a hollow. This quick visual could do with a more precise technique, but even subjectively the gasket is half to a third the effective durometer. Interesting as well that as the gasket is compressed, a solid, traditional gasket has a somewhat linear increase in resistance. The hollow gaskets have minimal initial resistance and then rapidly increases once the hollow is collapsed.

One concern was whether the gasket could recover once collapsed and as seen in images five and six, the recovery is excellent with this 60102 material.

Images five and six also brought to light the fact that hollow gaskets do not require the same UV intensity of solid gaskets simply because there is less material the UV light needs to penetrate. This enhances the ability of low intensity systems to yield excellent results.

Image seven is simply a fun visual indicator of the difference between solid and hollow gaskets. By using a pin across both a solid and hollow gasket, it is easier to get an appreciation for the difference!

    The same technology that allows for hollow gasket dispensing allows for a simple transition to filling the hollow with something other than air. Currently in our trials we have filled the hollow with black RTV. As the outer "insulator" is transparent, the consistency becomes readily verifiable.
This represents a step forward from our previous work done back in 2006 with dispensing conductive traces on acetate sheet.
While the photos show a single conductor, multiple conductors are possible and our trials have been successful with up to seven conductors.

Please note that electrical connections to these wires present certain challenges! Potential interconnect methods are:
1) Pierced wires (insulation displacement style interconnect)
2) Snap style (YKK Snapet Ligne 14 for example)
3) Z axis conductive adhesives
4) Embedded and encapsulated one-time-use electronics.

As it is also possible to multiple spaced conductors with a hollow center, it becomes possible to implement a clamping ring vis-a-vis the Imperial Eastman pneumatic fitting.
All if these methods however would require further encapsulation to preserve the interconnect.

    ICP Rabbit Line Configuraiton 24" x 24" x 3" (600mm x 600mm x 75mm)
This particular configuration was developed a number of years ago, but recent enhancements have made this worth noting again. This design has gone from an 11" x 11" area to a 24" x 24" area. Surprisingly, the reason for this development was an index table application that required the larger dispense area.
An added attribute of the new design is the capacity for much greater head payloads. This design exhibits minimal deflection even with head configurations exceeding 20

    Peristaltic pump integration for precision bottle filling

Peristaltic pumps are essential in food and medical applications as they provide the manufacturer with a disposable fluid path. Hose sets are available to meet a variety of regulatory needs.
Peristaltic pumps are in the positive displacement class of pumps. With appropriate controls, +/- 0.2ml precision can be achieved and our work continues on improving this precision.
Our pump rate at this precision is 720ml/minute. We are intent on improving this as well.

Out of frustration with existing peristaltic pumps and born of a certainty we could improve things, our version of the classic traditional was designed. Enhancements such as peristaltic rotor tracking through encoder feedback enhance volumetric accuracy. Built in fluid leak detection and integration with the CP system's interlock chain provide assurance and confidence that even should problems occur, the system will react in a controlled way. The belt reducer incorporated in this design enables the low cost stepper motor to operate in its most efficient torque zone and provide the best possible fill rate while mitigating splash.
Only the bearings, motor, drive, tubing, and shafts are purchased. All other components of the pump are made efficiently in-house, making customizations easy. We can provide custom tube occlusion, rollers per rotor, and even multiple tube counts at need. Off the shelf 2, 3, and 4 roller rotors are available.

UPDATE: Long term production QC monitoring shows a repeatability of 0.50 ml. Recent testing with platinum cured silicone tubing has improved the volumetric accuracy bu 10% or +/-0.45 ml.