Rapid automation of HDD disk surface metrology for production
Project snapshot
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Challenge
Scale precise disk surface scanning from lab to high-volume production
Candela Instruments had proven their optical surface scanning technology on a manually loaded machine, but expanding to full production required a fully automated, in-line system. The automation had to precisely handle, load, and flip disks for dual-sided scanning, integrate with factory systems, and meet aggressive throughput, space, and cost targets—all while maintaining high precision for reliability testing and failure analysis.
Innovation
Custom robotic automation to bridge lab and production environments
We collaborated with Candela to define automation specifications and ensure seamless integration with both Candela and end-user requirements. Key elements of the solution included:
- Development of a custom robotic manipulator to precisely load disks onto a vacuum chuck for high-speed rotation.
- Robotic arm with a direct-drive rotational axis enabling fast, efficient disk flipping and dual-sided measurement.
- Compact design capable of navigating within the machine’s limited space while maintaining high throughput.
- Close collaboration with Candela and the end-user to define automation requirements early in the development process.
- Full integration into factory systems to support high-volume production.
Result
Industry-standard metrology automation delivered rapidly
The first automated system was ready for high-volume production in just 12 weeks. The tool became the standard of excellence in the HDD industry, with more than 230 fielded units. Candela Instruments was later acquired by KLA, and AIR continues to manufacture the system, demonstrating enduring reliability and market acceptance.
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