OLYMPUS Stream Software 1.9The all-in-one measurement solution for quality assurance

The optical microscope is used as a key part of the quality assurance (QA) process

in many different industries to ensure that components are manufactured according

to exact specifications, before being assembled into the end product. Implementing

quantitative measurements, such as coating thickness evaluation and the validation

of geometrical product specifications (GPS), ensure accuracy is achieved within the

correct tolerance range for each product. As such, these form the core of QA in sectors

as diverse as medical engineering, electronics, and the automotive industry.

Therefore, the materials science micro-imaging software must be both comprehensive

and flexible in order to allow the system to perform this diverse range of tasks, while

adhering to international standards for quality control. The Olympus Stream 1.9

software is the most comprehensive solution for managing every task, from image

acquisition to data management (Figure 1). The concept of modularity is a cornerstone

of this modern software and enables a high level of flexibility for managing a range of

different tasks, as well as the ability to future-proof. Add-on packages for more specific

tasks, such as automatic measurement, means the Stream software can be tailored to

individual requirements and future applications.

For microscopy applications within QA, each task must be managed by the micro-

imaging software at every stage of the process. This white paper will outline how

OLYMPUS Stream 1.9 has adopted the latest digital technologies to achieve advanced

performance, along with intuitive operation for every task, and how these enhance the

following steps of the workflow:

1. Image acquisition and refinement

2. Measurement

3. Data management

4. Report creation

Application note

Stream software at a glance

· An advanced tool for microscopy-

based quality assurance tasks

· A comprehensive solution for the

complete micro-imaging workflow

· Modular design affords flexibility and

future-proofing

· Achieves a high level of automation

for the industrial microscope

· Diverse measurement functions

adhering to latest quality standards

Solutions

· Advanced image acquisition and

refinement techniques

· More than 50 measurement

functions

· Pre-defined specialized

measurement solutions

· Efficient data management

· Report creation with Microsoft Word

compatibility

Key words

· Micro-imaging software

· Quality assurance

· Geometrical product specifications

· Coating thickness evaluation

· Automatic measurement

1. Image acquisition and refinement

When employing optical microscopy for evaluating the quality of a component, the workflow

begins with image acquisition. Since image quality dramatically impacts inspection and

measurement further down the line, accurate image acquisition is crucial. With the latest

micro-imaging software, the quality of image acquisition is improved to capture the

finest details of a sample. In the past, generating high-contrast and fully-focused images

presented a significant challenge. A sample is rarely flat, homogenous, and small enough

to fit into the field of view. Digital image-processing tools are now available that essentially

work by forming a composite image from multiple capture areas - expanding the field of

view, extending the depth of focus, and improving contrast.

· Expanding the depth of focus: Micromechanical parts are 3D in nature,

making it impossible to generate a fully focused image using optical microscopy

alone. Utilizing fine focus adjustment and digital technologies, the Extended

Focus Image (EFI) merges multiple images at different z-levels, forming a

single, fully-focused composite image from the most uneven surfaces (Figure

2). In doing so, EFI facilitates the inspection of many different 3D samples,

from dental equipment to the miniature components of a watch mechanism.

· Expanding the field of view: The traditional microscope has a limited field

of view, and generating a complete high-resolution image for analysis and

documentation can be challenging for larger samples. Overcoming this limitation,

the Multiple Image Alignment (MIA) function is an image-stitching tool, which

generates a single panoramic view from multiple images (Figure 3) at any

magnification. Effectively expanding the field of view in this way allows the in-depth

microscopic inspection of larger samples, complete components, for example.

· Improving dynamic range: Samples often contain a mixture of both bright, highly

reflective features, as well as darker and low-reflective features. Therefore, a single

exposure time is not sufficient to capture the details of both features on a single

image due to limited camera contrast, compromising measurement accuracy.

To make all image areas visible at the same time, the High Dynamic Range (HDR)

capability automatically acquires a series of images at varying exposure times and

merges them to form a single composite image. Generating a single high dynamic

range microscopic image with the HDR function therefore enables the accurate

measurement of all features (Figure 4).

Even for the most experienced operators, acquiring the perfect image using a traditional

optical microscope system is often time-consuming. It can be even more challenging for

those less experienced operators, and a particularly powerful feature of the latest Stream

software overcomes this with the facility to incorporate a high level of automation. Reducing

operator involvement in this way is beneficial in terms of time saved, as well as repeatability,

producing consistent (and therefore comparable) results. For example, it can be laborious to

set the optimum focus for each sample image, and the Stream software autofocus function

speeds up this process by automatically generating fully-focused images. Furthermore, the

additional integration of a motorized stage also enables advanced functions, including MIA,

EFI, and HDR to be fully automated.

Application note

Figure 1: Getting connected. OLYMPUS Stream 1.9 software integrates the complete workflow, from image acquisition in the light microscopy (LM) and electron microscopy (EM) laboratories, to image processing, production, and quality assessment (QA).

Figure 2: Extending the depth of field. Extended Focus Image (EFI) creates fully focused images.

Figure 3: Expanding the field of view. High-resolution panoramic images are created with the Multiple Image Alignment (MIA) function, ideal for larger samples.

EM laboratory Management

LM laboratory Job processing

Intake Control

Production

QC

QA

CRM

LIMS

Server

Stream

Application note

2. Measurement

The level of quantitative information that can be gathered from a sample is reliant upon

the measurement capabilities of the micro-imaging software, and precision along with

adherence to quality control standards are of the utmost importance.

Traditional measurement approaches based on eyepiece reticles are time-consuming,

straining on the eyes and can also incur a level of inaccuracy. The advent of software-

based measurement overcomes these limitations, vastly improving precision even at high

magnification, while also allowing for a greater range of parameters to be measured. Since

many different sample materials, shapes, and sizes must be measured, with different

features of more interest for certain tasks, the diversity of interactive measurement functions

is important. The Stream software includes distances, angles, rectangles, circles, ellipses,

and polygons for precisely this purpose. However, it is also true that different companies

will also implement more specific applications, demanding highly specialized measurement

capabilities. This is where a modular approach to software design is beneficial, allowing the

user to build their own software system. For example, module options, or “Solutions,” can

be added to the basic Stream 1.9 software, allowing for coating thickness and automated

measurement capabilities.

2.1 Measuring coating thickness

Evaluation of coating thickness is a standard task throughout many industries, in physical

and chemical vapor deposition of thin films used in semiconductor production, for

example. Between a thickness of 1µm and 50 µm, this is often achieved for a variety

of different samples using top view imaging with the popular Calotest (or ball crater)

method. Following the application of a grinding sphere to a coating, optical inspection

of the depression is performed with the OLYMPUS Stream Calotest solution. Once the

boundaries of the individual coatings have been determined, this grinding pattern geometry

is used alongside the diameter of the grinding ball and sample geometry to calculate the

coating thickness (Figure 5a). An alternative approach for evaluating thicker coatings, such

as paints or composite plastics, is to visualize one or more layers of a cross-sectioned

sample, using the Stream Layer Thickness software, where the shapes are defined and the

layers automatically measured (Figure 5b).

2.2 Automatic Measurement

Automatic measurements reduce the associated manpower and cost, while dramatically

enhancing repeatability between different users. Removing any deviations arising

from different operators ensures consistency in the data generated, and therefore, the

precision of recorded dimensions. The latest Stream software incorporates edge-detection

capabilities, meaning that a range of measurements can now be performed without input

from the operator. Furthermore, multiple measurements can be taken from a single image.

A validation tool generates a pass/fail flag for every measurement, making these tools

particularly beneficial for more complex components such as the silicon wafer (Figure 6).

Once data has been generated from the desired set of measurement functions, statistical

analysis carried out may include a variety of different tests. Standard analysis, including

mean, standard deviation, minimum and maximum values can be performed within the

Stream software. Alternatively, to allow for integration into the existing workflow, the data

can be exported into third party programs for further interrogation.

Figure 4: Enlarged dynamic range. High Dynamic Range (HDR) generates images with all image details visible simultaneously – the bright as well as the dark.

Figure 5: Evaluating coating thickness. Coating thickness can be evaluated by: A) Using the Calotest method; and B) Imaging a cross-section sample.

Figure 6: Precision engineering with automatic measurement. wafer pattern is automatically detected and measured using pattern recognition and a matching pattern (red) for correct identification.

A B

Application note

3. Data Management

Quick access to data generated from the manufacturing process is incredibly important,

even once the end product is fully formed. Data generated from microscopy-based

QA procedures may need to be retrieved at any phase of the process, or even months

after production, in the unfortunate event of product failure, for example. In such cases,

traceability back to source components can identify the origin of a fault, and archived QA

data determines liability. Of benefit in all industries, this traceability is particularly important

within the automotive and medical device sectors, in which safety is of paramount

importance.

The ability to accurately trace a component not only reduces the time between detection

and correction of any faults, but also limits product recall only to those items containing

the faulty component, thereby resulting in significant cost savings. Stream 1.9 software

facilitates this process through ensuring efficient data management for microscopy-based

QA tasks.

Since a single microscope system may contain archives of thousands of samples,

retrieving the relevant data can be particularly challenging. Stream 1.9 software solves

this problem by allowing the operator to identify an archived document from a range of

user-definable classifications and keyword associations. For example, in the event of a

customer complaint, the relevant sample documents can be retrieved based on the date

or keywords relating to aspects such as the production process or materials used. All

image-related parameters and measurement results are logged alongside the document,

providing insight into the sample characteristics long after manufacture. In addition to pre-

set fields, a free-text field allows additional data to be entered for quick retrieval.

4. Report Creation

Results need to be communicated in a clear and accurate manner, while adhering to the

company’s in-house style and format. As one of the four key stages of the materials science

workflow, Stream 1.9 software includes many features to streamline this task. The software

allows highly customizable reporting capabilities, with full Microsoft Office integration

allowing the creation of professional reports via Word and presentations via PowerPoint.

Supporting the latest Windows 8 operating system and file compression methods also

ensures that report files can be easily managed and shared via e-mail.

A solution for every task

As the “brains” behind the industrial optical microscope, today’s micro-imaging software

harnesses the latest developments in digital technology to overcome the many challenges

faced by QA departments. As one such program, Olympus Stream 1.9 integrates an

incredibly diverse array of tasks covering every stage of the workflow, within a single

comprehensive software solution. Innovative capabilities and a dynamic user interface

allow detailed inspection and measurement tasks to be performed quickly and easily, with

minimal knowledge of microscopy.

Including turnkey materials measurement solutions, the Olympus Stream 1.9 software can

also be optimized for a range of specific microscopy-based measurement applications

such as coating thickness evaluation and automatic measurement – both important

aspects of QA. This comprehensive and flexible platform allows the user to build the

software around their requirements, streamlining the materials science workflow and

transforming the Olympus optical microscope into a single dedicated solution for materials

science applications.

For more information on the latest Olympus Stream 1.9 software, please visit

www.olympus-europa.com

Application note

Please contact

Ralf Schäfer

(Marketing Communications Manager

Microscopy)

Olympus Europa Holding GmbH

Hamburg, GER

T: +49 (0) 40 23773 5913

F: +49 (0) 40 23773 505 913

E: microscopy@olympus-europa.com

Web: www.microscopy.olympus.eu

Victoria Coupe (Text)

(Account Manager)

Alto Marketing

Southampton, UK

T: +44 (0) 1489 557 672

F: +44 (0) 1489 559 246

E: victoriac@alto-marketing.com

Web: www.alto-marketing.com