Three Dimensional Imaging of LIGA-Made Microcomponents

Nickel and nickel-alloy microparts sized on the order of 5-1000 microns have been imaged in three dimensions using a new microscopic technique, Digital Volumetric Imaging (DVI). The gears were fabricated using Sandia National Laboratories' LIGA technology (lithography, molding, and electroplating). The images were taken on a microscope built by Resolution Sciences Corporation by slicing the gear into one-micron thin slices, photographing each slice, and then reconstructing the image with software. The images were matched to the original CAD (computer aided design) model, allowing LIGA designers, for the first time, to see visually how much deviation from the design is induced by the manufacturing process. Calibration was done by imaging brass ball bearings and matching them to the CAD model of a sphere. A major advantage of DVI over scanning techniques is that internal defects can be imaged to very high resolution. In order to perform the metrology operations on the microcomponents, high-speed and high-precision algorithms are developed for coordinate metrology. The algorithms are based on a leastsquares approach to data registration the {X, Y, Z} point clouds generated from the component surface onto a target geometry defined in a CAD model. Both primitive geometric element analyses as will as an overall comparison of the part geometry are discussed. Initial results of the micromeasurements are presented in the paper.