MANUFACTURING AND ASSEMBLING.md

Parts of the Traveling Microscope

Base

The base provides stability and support for the entire microscope. It is usually a heavy and flat structure to ensure
the instrument remains steady during measurements.

• Initially, a detailed design for the base was created, taking into consideration the dimensions of the
  microscope components and the stability needed.
• Then the metal plate was cut according to the design by using a grinder.
• The edges and corners of the metal plate were smoothed using a metal file.
• The locations for holes needed to mount the vertical pillar and other components of the microscope
  were identified.
• These holes were drilled using an appropriate-sized drill bit.
• The microscope components were assembled onto the base, securing them in place with screws and bolts.

Vertical Pillar or Column

The vertical pillar or column rises from the base and provides vertical support for the rest of the microscope
components. It is an essential part of the structural framework.

• Primarily, a detailed design for the vertical pillar was created, considering the required height, stability,
  and any specific features.
• The box bars were cut according to the design using a bar cutter machine or hacksaw.
• The locations for holes needed were marked and those holes were drilled using an appropriate-sized drill bit.
• Then the thin slot was made by using the milling machine.
• The edges and corners of the box bars and thin slot were smoothed using a metal file.
• Then the interior mechanism of the pillar was designed, considering the functionality required for
  adjusting the height of the microscope body.
• A spring was used to assist in raising or lowering the microscope body.
• The appropriate location for the spring within the mechanism was identified and a hollow cylinder was
  used to maintain a proper movement of the spring.
• Then the hollow cylinder was welded to the bottom of the vertical pillar and the spring was placed inside
  the cylinder.
• An iron rod was used to keep the smooth vertical movement of the microscope body.
• Then the microscope body was attached to the iron rod using an iron bush and a bolt. Large movement
  of the microscope body can be done by tightening and loosening this screw.

Microscope Body or Barrel

The microscope body houses the optics, including the objective lens and eyepiece. It is attached to the vertical
pillar and can be moved up or down for focusing.

• Primitively, a design for the body or barrel was created, considering the required dimensions and specifications.
• Attention was given to accommodating the optical components and providing structural stability.
• Metal pipes were cut to the desired lengths based on the design specifications, using metal cutting tools
  such as a hacksaw, angle grinder, or metal cutting bandsaw.
• The cut metal pipes were shaped as per the design requirements using metalworking tools.
• This involved removing sharp edges by using a metal file; a smooth and even surface was created using a
  lathe machine.
• Then a groove was created to prevent rotation around the axis of the inner barrel. A milling machine was
  used for this task.
• As the necessary mechanism to adjust the focus length, a hole was made on the outer barrel and a screw
  was inserted through it.
• The various components, including lenses and eyepieces, were assembled onto the metal pipes.
• Then the outer barrel was welded perpendicularly to another iron rod using a welding machine, and that
  whole system was attached to the vertical pillar.
• The assembled metal pipes were checked for any sharp edges or imperfections.
• Any irregularities were addressed, and the surface was finished to ensure a polished and professional appearance.

Screw and Nut Mechanism

The microscope's movement is controlled by a screw and nut mechanism. This allows precise and controlled
motion along the vertical pillar, enabling accurate focusing on the specimen.

• A design for the screw and nut mechanism was created, considering the required precision and control
  for the movement of the microscope along the vertical pillar. Then a metal box was made to be slightly
  larger than the vertical pillar. A suitable screw was chosen based on strength and durability.
• To attach the end of the screw, a metal knob was built.
• The appropriate knurling tool for the desired knurl pattern was chosen.
• The lathe speed was adjusted to a moderate speed suitable for knurling, and the knurling tool was
  positioned on the metal rod, ensuring it was aligned perpendicular to the axis of the rod.
• The lathe was started, and cutting oil or lubricant was applied to the metal rod and knurling tool to reduce
  friction and heat generation during the knurling process.
• The knurling process was repeated with adjustments to the tool pressure or feed rate until the desired
  knurl pattern was achieved.
• Once the knurling was complete, any burrs or rough edges from the ends of the knurled section were
  removed using a file.
• Then threads were cut into the metal box using thread-cutting tools, and the knob was welded to the end
  of the screw.
• The assembled screw and nut mechanism underwent thorough testing to ensure smooth and controlled
  motion along the vertical pillar of the microscope.
• Once installed onto the vertical pillar of the traveling microscope, the large movement of the microscope
  body could be controlled by tightening and loosening the screw.

Fine Adjustment Knob

The fine adjustment knob allows for precise focusing of the image. It is used to make small adjustments to the
position of the microscope body for accurate measurements.

• Using a similar procedure, a fine adjustment screw was made and installed onto the vertical pillar at the top.
• Using this knob, small adjustments to the position of the microscope body can be operated.

Main Scale and Vernier Scale

Traveling microscopes often include scales and verniers for measuring the linear dimensions of the specimen.
These scales are typically graduated and can be read with high precision.

• Both main and vernier scales were designed using AutoCAD.
• The drawing settings, including units, grid, and dimensions, were configured according to the requirements
  of the vernier scale design.
• The appropriate drawing tools, such as lines, circles, and text, were selected from the AutoCAD toolbar.
• The main scale was designed by drawing a straight line with the appropriate length and marking the
  divisions corresponding to the measurement units.
• The vernier scale was drawn parallel to the main scale, by dividing 19mm into 20 parts (smallest
  measurement can be taken = 0.05mm).
• Numerical values representing the measurement units were added to both the main scale and the vernier
  scale using text tools in AutoCAD.
• The completed vernier scale design was saved in the desired file format and printed as a sticker. Then
  the scale was stuck onto the vertical pillar.

Lens Holders

• The lens holders were also designed using AutoCAD software.
• The appropriate design tools in AutoCAD, such as lines, circles, and 3D modeling features, were selected
  for creating the lens holders.
• The measurements and specifications of the microscope's lenses were analyzed to ensure the accurate
  design of the lens holders.
• Multiple designs for the lens holders were sketched in AutoCAD, considering factors such as shape and size.
• Once the designs were finalized, they were exported from AutoCAD in a compatible file format, such as
  STL or OBJ, for 3D printing.
• The prepared design files were transferred to the 3D printer, and the printing process was initiated.
• The 3D printer manufactured the lens holders layer by layer using the chosen printing material.
• After printing was completed, the lens holders were inspected for any defects and installed onto the
  microscope assembly.