Precision Sensor Mounts for Laboratory Automation
Application
Liquid Handling Sensor Mounting
Material
Aluminum 6061-T6
Quantity
8 units
Process
3-Axis CNC Milling
Finish
Clear Anodize Type II, 10–20 µm
Lead Time
8 business days
Engineering Challenge
Position an optical sensor to sub-millimetre accuracy inside a liquid-handling cell, on a batch of eight units, with repeatable replacement when a sensor is swapped during service.
DFM Analysis
Locating features reviewed so the sensor datum is set by dowel pins rather than by bolt clearance. Bore sizes checked against the sensor body with an allowance for anodizing growth. Non-critical faces left on general tolerances to keep the per-unit cost sensible at a batch of eight. Serial marking proposed so service records can reference each mount.
Manufacturing Solution
Mounts machined and inspected in a single setup for the locating faces, with bores finished to the specified fit after the anodizing allowance was confirmed. Dowel pins fitted for repeatable location, serial numbers marked on a non-functional face, and each unit individually protected for shipment.
Inspection Method
Critical-dimension report covering bore positions, locating pin positions and mounting heights, plus a functional fit check with a customer-supplied sensor body before the batch was released.
Final Result
Eight mounts delivered and installed with the sensor positioned within specification on first assembly. The customer has since reordered the same mount with a modified bracket arm for a second instrument.
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