Case Study: Rapid Design Process for a High-Velocity and Accurate Linear Stage in an Optomechanical Device

Abstract

Abstract This paper showcases how the design process execution in a challenging environment where cost, time, and COVID-19 induced supply chain factors are significant considerations. The design process was executed in six phases: defining SMART (specific, measurable, attainable, relevant, time-bound) requirements, concept development, concept selection, risk reduction prototyping, final design, and verification testing. Defining SMART requirements is critical to quickly define the design scope which allows for a time-efficient and targeted approach during the subsequent phases. Positional accuracy and speed requirements were the most critical functional requirements. Next, we engaged in a concept development phase, which involved exploring existing designs and novel concepts, with input from subject matter experts familiar with the design space. Two concepts emerged as reasonable approaches: a direct-drive linear motor-based design and a lead-screw based design which were initially developed in parallel. To narrow down the design space, a concept selection phase was used to analyze the advantages and disadvantages of each concept, factoring in the weighted relative importance of each design requirement. The linear motor-based design was determined to best fit the design requirements and proceeded into risk reduction prototyping. Risk reduction prototyping involves design and creation of limited prototypes to learn the key limitations of a design with respect to the requirements, and iterate the deficient qualities in a short feedback loop. By leveraging readily available components a stage assembly representative of the final design was constructed and demonstrated that critical design requirements could be met. The final design was created and fabricated followed by verification testing to ensure the final stage design met the SMART requirements defined in the outset.