In today’s high-precision manufacturing environments — medical devices, aerospace and defense, micro-molded plastics — part sizes are shrinking. Tolerances are tighter. And consistency is non-negotiable.
But as parts get smaller, singulation gets harder.
At Sure Controls, we believe no part is too small to automate. And when paired with flexible feeding solutions like the Asycube from Asyril, even the most delicate, lightweight components can be reliably separated and presented for robotic picking.
Here’s how to improve singulation performance — especially when working with micro and small-format parts.
Why Small Parts Are More Challenging
Miniaturization introduces unique dynamics:
- Static buildup
- Part clinging and nesting
- Lower mass response to vibration
- Increased overlap
- Tighter vision tolerances
Traditional bowl feeders often struggle at this scale. Flexible feeding systems, however, are designed to adapt — when properly tuned.
1. Tune Vibration for Low-Mass Components
With small parts, more vibration is rarely better.
The Asycube’s 3-axis vibration technology allows controlled directional movement. For lightweight parts:
- Use lower amplitude settings
- Fine-tune frequency for surface response
- Avoid aggressive motion that causes stacking
Micro parts require finesse — not force.
2. Control Static and Surface Conditions
When parts weigh fractions of a gram, static electricity becomes a major variable.
Consider:
- Anti-static ionization
- Humidity control
- Surface cleanliness
- Material compatibility of the feeding plate
Even slight static cling can prevent proper separation.
3. Optimize Part Density on the Plate
Overcrowding is especially problematic for small parts.
Instead of maximizing surface coverage:
- Maintain lower part density
- Use controlled hopper feed rates
- Allow vibration to create natural spacing
Throughput is driven by consistent singulation, not maximum part volume.
4. Refine Vision Parameters for Micro Detection
Smaller parts mean tighter detection thresholds.
When integrating with systems like Asyfill:
- Adjust lighting angles to reduce glare
- Increase contrast between part and plate
- Fine-tune blob analysis and contour detection
- Filter overlapping geometries
At micro scale, lighting often matters more than vibration settings.
5. Engineer the Pick — Not Just the Feed
When parts are extremely small, gripping strategy is critical:
- Micro vacuum cups
- Precision mechanical grippers
- Optimized approach angles
- Reduced robot acceleration profiles
Improving pick stability can dramatically increase overall system reliability — even if feeder settings remain unchanged.
6. Design for Automation When Possible
If you’re in early product development, small geometry tweaks can dramatically improve singulation:
- Break symmetry
- Add micro locating features
- Modify surface texture
- Reduce nesting tendencies
Collaborating early between engineering and automation teams can eliminate downstream challenges.
No Part Too Small — Why It Matters
At Sure Controls, our expertise extends beyond a single feeder platform. We specialize in flexible feeding solutions engineered for:
- Micro medical components
- Small stamped metal parts
- Precision molded plastics
- High-mix electronics assemblies
Where others may say a part is “too small” or “too difficult,” we engineer the process — feeder, vision, robotics, and tooling — as one integrated solution.
Miniaturization isn’t a limitation. It’s an opportunity for smarter automation.
The ROI of Getting Singulation Right
Even slight improvements in singulation for small parts can yield:
- Higher pick success rates
- Reduced operator intervention
- Improved OEE
- Less scrap and rework
- Faster changeovers in high-mix environments
For high-value, small-format components, precision equals profitability.
Final Thought
As parts continue to shrink, automation strategies must evolve. Flexible feeding systems like the Asycube enable manufacturers to scale without compromising accuracy — but performance depends on careful tuning and system-level thinking.
If you’re struggling with micro-part singulation or were told your components are “too small” to automate, it may be time for a second look.
At Sure Controls, there’s no such thing as too small.
Yes. Flexible feeding systems like the Asycube from Asyril are designed to manage small and micro components when properly tuned. Adjusting vibration settings, lighting, and pick strategy allows even delicate parts to be reliably singulated.
Improving performance typically involves:
Reducing part density on the feeder plate
Fine-tuning vibration amplitude and frequency
Optimizing lighting and vision detection
Selecting the right gripper and robot approach
Small adjustments across the entire system often produce significant gains in pick reliability and throughput.
Small parts present unique challenges because they:
Have lower mass and respond differently to vibration
Can overlap or nest together
Are more susceptible to static electricity
Require tighter vision detection tolerances
As part sizes decrease, precision in feeding, lighting, and picking becomes increasingly critical.
Key Takeaways
- Small part singulation is challenging due to factors like static buildup, nesting, and tighter tolerances.
- Operators can improve singulation performance by tuning vibration settings, controlling static, and optimizing part density on the feeding plate.
- It is important to refine vision parameters and design the pick strategy for better stability with micro components.
- Engineers can enhance automation during product development by adjusting geometries and features to reduce nesting tendencies.
- Achieving accurate singulation leads to higher efficiency, reduced interventions, and increased profitability in manufacturing environments.