In order to scale the planar flow casting (PFC) process to industrial levels a Python model is created. The model which is based on a combination of empirical and theoretical equations, is used to explore the limits of the process. The model is independently verified with a Comsol simulation, which is extended with solidification and heat transfer physics. The model is then used as a bases for a system and control simulation of the complete planar flow casting system. Extra elements are added, such as thermal expansion, out of roundness of the wheel, crucible and actuator mechanics, and sensor behaviour. The controllability of the system using a PID controller is presented. With this knowledge, the design requirements for the adjustment of the existing PFC machine were defined, qualitatively as well as quantitatively, for the nozzle, pressure system and gap sensor. Following this, the microstructure of the material produced by the free flow casting (FFC) process is analysed. The microstructure is measured using XRD, SEM and EDS techniques. These measurements are then compared with a model based on the Scheil equation and a kinetic phase diagram, developed for the aluminium silicon alloy. The microstructure found consisted of primary silicon particles in which a significant amount of aluminium was dissolved, as predicted by the material model. The silicon particles are dispersed within an aluminium silicon eutectic matrix with rounded needle like features. The silicon particle size is in the order of 5 μm, whilst the feature size in the eutectic is in the order of 100 nm.

To assist in the fast alignment of tiny components, Prodrive Technologies has developed a type of camera system called the Component Alignment Sensor (CAS) that is used on a pick-and-place machine. The system uses an optical target as the reference during its assembly and final testing steps. Two main components of the target are a glass reticle and a stainless steel carrier that are bonded together. These two components need to be precisely aligned w.r.t. each other. Till now, the alignment between the reticle and carrier has been performed manually by relative movement between them created by hand. However, this method has some limitations, including, but not limited to, an increase in the alignment time and sensitivity to external jerks or disturbances. Accordingly, the thesis objective is to create a (detailed) design of an alignment mechanism to perform the 3-DOF in-plane alignment in µm and sub-mrad level. The research starts with the formulation of design requirements, followed by concept design, evaluation and selection, and finally a detailed design of the mechanism. A flexure-based alignment mechanism was proposed and designed that uses fine screws for actuation. Various design principles were applied to construct a stiff and compact mechanism that uses a limited number of adjustment steps for the alignment. The process was supported by calculations and analyses that contributed to decision making. Besides, the assembly and alignment procedures of the alignment mechanism were described. The thesis is concluded with a plan to verify if the matured design meets the set requirements.