Overview
A manufacturer of automated laboratory storage systems required a highly precise stacking structure for robotic sample storage carousels used to manage microplates in pharmaceutical and laboratory environments.
The challenge required an innovative manufacturing and assembly approach capable of delivering exceptional dimensional accuracy, repeatability, and structural stability while remaining cost-effective for production. Artmetco developed new fabrication and assembly methods that enabled reliable, high-precision production of these complex storage assemblies.
The Challenge
Automated laboratory storage systems rely on robotic handling to repeatedly retrieve and store microplates without damaging samples or compromising positioning accuracy.
The stacking structures needed to:
- Accommodate up to 24 storage shelves in a compact assembly
- Maintain shelf spacing within ±0.005 inches
- Limit shelf tilt to ±1°
- Prevent microplates from shifting or tipping during carousel movement
- Allow robotic insertion and removal without interference
- Be manufactured efficiently without relying on expensive full-machining processes
Conventional manufacturing methods presented significant limitations.
Fully machined structures could achieve the required precision but were prohibitively expensive, while welded assemblies introduced dimensional variation that exceeded acceptable tolerances. Simultaneously bending dozens of structural features at different angles with consistent repeatability also exceeded conventional sheet metal forming capabilities.
Artmetco’s Approach
Artmetco developed new manufacturing processes and assembly concepts specifically designed for high-precision laboratory automation components.
Innovative Shelf Forming Process
A new sheet metal design was developed using:
- Precision-cut stainless steel side panels
- Continuous formed shelf flanges
- Integrated retention tabs
- Anodized aluminum structural components with Teflon-treated interfaces
The process enabled shelf supports and retention features to be created directly from the side panels while maintaining exceptional dimensional consistency.
Advanced Multi-Stage Forming
Rather than individually bending each feature, Artmetco engineered a custom forming process capable of producing multiple bends simultaneously.
The solution incorporated:
- Spring-loaded forming plates
- Custom punch-and-die tooling
- Multi-stage bending operations
- Specialized lever and roller mechanisms for secondary forming
This approach allowed dozens of shelf features and retention tabs to be formed accurately while significantly improving production efficiency.
Precision Assembly Engineering
To maintain tight tolerances throughout assembly, Artmetco developed new fixture and alignment concepts incorporating:
- Simultaneous multi-pin insertion
- Pneumatic positioning systems
- Controlled insertion force distribution
- Precision clamping fixtures
- Optimized alignment tooling
The team also identified the impact of Teflon coating residue on threaded assemblies and developed improved preparation methods to ensure repeatable assembly accuracy.
Technical Innovations
The project generated valuable manufacturing knowledge in several key areas:
- High-precision sheet metal forming for laboratory automation components
- Simultaneous multi-feature bending processes
- Precision fixture design for repeatable assembly
- Controlled pneumatic alignment techniques
- Improved assembly methods for coated precision components
- Cost-effective alternatives to full-machined assemblies
Business Impact
By developing innovative manufacturing and assembly methods, Artmetco enabled the production of highly accurate sample storage structures suitable for automated laboratory environments while significantly improving manufacturing efficiency.
The project demonstrates Artmetco’s ability to:
- Manufacture complex precision assemblies for laboratory automation
- Develop efficient production methods for tight-tolerance sheet metal components
- Support high-performance robotic handling systems
- Deliver repeatable quality for regulated laboratory applications
- Solve complex manufacturing challenges through engineering-driven process development
