Welded Micromanipulator Rods for TEM Lift-Out

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Solution Overview

Problem

Current lift-out techniques for micromanipulators in TEM sample preparation are inefficient due to the frequent need to reshape and replace the needle tip, which consumes time and reduces system uptime, as the needle is consumed during each use and requires lengthy re-shaping processes.

Innovation Solution

A chip with prefabricated rods that can be easily attached to the micromanipulator, allowing for quick replacement and extension of the needle tip, reducing the frequency of venting the specimen chamber and increasing system uptime, with the rods being produced using methods like tungsten deposition and XeF2 on a mold, and attached via welding or other mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the micromanipulator needle is repeatedly used for lift-out operations, then the needle is consumed and requires re-shaping, but the re-shaping process takes 30-75 minutes and reduces system uptime

Engineering Contradiction:

Improvesystem uptimeVSAvoidtime for needle re-shaping

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The micromanipulator system is segmented into a reusable manipulator body and disposable needle tips. The needle tip is separated as a consumable component that can be quickly replaced without affecting the main manipulator, eliminating the need for time-consuming re-shaping operations and maintaining system uptime.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The needle tip is designed as a disposable, short-living component that is replaced rather than re-shaped. This approach treats the needle as a consumable item that can be quickly exchanged, eliminating the 30-75 minute re-shaping process and associated system downtime.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If the needle tip is frequently replaced or re-shaped, then the system can maintain operational capability, but the specimen chamber must be vented frequently reducing efficiency

Engineering Contradiction:

Improveoperational capabilityVSAvoidoperational efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Multiple needle tips are pre-loaded onto the manipulator assembly in a vacuum-compatible manner. This preliminary preparation allows the system to maintain vacuum conditions while having ready-to-use needle tips, eliminating frequent venting operations and maintaining both reliability and productivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manipulator assembly is designed to accommodate multiple needle tips universally, allowing quick switching between pre-loaded tips without venting the chamber. This multi-functionality ensures operational reliability while maintaining high productivity by avoiding frequent vacuum breaks.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If the needle is milled into the desired shape from a cone, then the correct end form is achieved, but the process time increases as the needle is consumed

Engineering Contradiction:

Improveneedle end form precisionVSAvoidtime to shape the needle end

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The needle tips are pre-formed with the correct end geometry during manufacturing before being loaded onto the manipulator. This preliminary precision formation eliminates the need for time-consuming in-situ milling operations, providing both manufacturing precision and time efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The needle tip is designed as a disposable component that comes pre-formed with the correct geometry. By replacing rather than re-shaping, the system maintains manufacturing precision while eliminating the time loss associated with repeated milling operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution significantly reduces the time required to manage the needle end form and minimizes the frequency of exchanging the end form, enhancing operational efficiency and reducing downtime by allowing for rapid attachment and reuse of prefabricated rods.

Implementation Method 1

produced using methods like tungsten deposition

Methodology Applied

Scientific EffectTungsten deposition: Physical Vapour Deposition

Implementation Method 2

produced using methods like tungsten deposition and XeF2 on a mold

Methodology Applied

Scientific EffectXeF2 etching: Chemical Beam Epitaxy

Implementation Method 3

attached via welding or other mechanisms

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP3637453A1GIS welded micromanipulator extensions

Publication Date: 2020.04.15 FEI CO

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AI summary

The present invention provides a chip comprising: a substrate; a plurality of rods which are freestanding and spaced from the substrate and spaced from each other, wherein each rod has, longitudinally, a first end portion and a second end portion; connectors for connecting each of the plurality of rods at both longitudinal end portions thereof respectively and holding them to the substrate, wherein each rod can be individually raised away from the chip for use by a micromanipulator by cutting a rod from the connectors at both first and second end portions thereof. The present invention also provides a micromanipulator and a system for preparing a micromanipulator.