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Abstract Microassembly systems utilizing precision robotics have long been used for realizing three-dimensional microstructures such as microsystems and microrobots. Prior to assembly, microscale components are fabricated using micro-electromechanical-system (MEMS) technology. The microassembly system then directs a microgripper through a series of automated or human-controlled pick-and-place operations. In this paper, we describe a novel custom microassembly system, named NEXUS, that can be used to prototype MEMS microrobots. The NEXUS integrates multi-degrees-of-freedom (DOF) precision positioners, microscope computer vision, and microscale process tools such as a microgripper and vacuum tip. A semi-autonomous human–machine interface (HMI) was programmed to allow the operator to interact with the microassembly system. The NEXUS human–machine interface includes multiple functions, such as positioning, target detection, visual servoing, and inspection. The microassembly system's HMI was used by operators to assemble various three-dimensional microrobots such as the Solarpede, a novel light-powered stick-and-slip mobile microcrawler. Experimental results are reported in this paper to evaluate the system's semi-autonomous capabilities in terms of assembly rate and yield and compare them to purely teleoperated assembly performance. Results show that the semi-automated capabilities of the microassembly system's HMI offer a more consistent assembly rate of microrobot components and are less reliant on the operator's experience and skill. 

Microassembly systems utilizing precision robotics have long been used for realizing 3-dimensional microstructures such as microrobots. Prior to assembly, such components are fabricated using Micro-Electro-Mechanical-System (MEMS) technology. The microassembly system then directs a microgripper through automated or human-controlled pick-and-place operations. In this paper, we describe a novel custom microassembly system, named NEXUS. The NEXUS integrates multi-degree of freedom (DOF) precision positioners, microscope computer vision, and micro-scale process tools such as a microgripper and vacuum tip. A semi-autonomous human-machine interface (HMI) is programmed by NI LabVIEW® to allow the operator to interact with the microassembly system. The NEXUS human-machine interface includes multiple functions, such as positioning, target detection, visual servoing, and inspection. The microassembly system’s HMI was used by operators to assemble various 3-dimensional microrobots such as the Solarpede, a novel light-powered stick-and-slip mobile microcrawler. Experimental results are reported in this paper that evaluate the system’s semi-autonomous capabilities in terms of assembly rate and yield and compare them to purely teleoperated assembly performance. Results show that the semi-automated capabilities of the microassembly system’s HMI offer a more consistent assembly rate of microrobot components.