VCM Assembly Tools Guide
Gear up for efficiency.
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VCM Assembling and filling procedure to create disc samples:
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How to assemble a D25 Disc Insert (Video)
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How to assemble a D20 Disc Insert (Video)
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VCM Assembling and filling procedure to create 2 mm diameter samples:
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How to assemble a D02 Insert (Video) - to-do
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VCM Assembling and filling procedure to create <1 mm diameter samples: - to add
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How to assemble a D01 Insert (Video) - in progress
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How to use separation foils
How to assemble a Disc Insert
Create flawless discs and coatings.
Correctly assembling the different inserts for the VCM process is critical for uniform and flawless samples.
To prepare a sample, the VCM insert must be assembled and filled with specimen material. The filling and assembly procedure of the VCM insert is illustrated in the image below.
Assembly
Piston
VCM Chamber
Lateral separation foil
Front foil
Sample
Front foil
Base plate
Step 1
Step 2
1. The procedure starts with the main body of the completely disassembled VCM Tool
2. The separation foil is placed on the lateral surface of the chamber.
3. The base plate with O-Ring is inserted. It is very important that the lateral surface is completely pushed down before the baseplate and the chamber are put together. Then, the circular bottom separation foil is placed on the base plate. This should be carried out with the supplied foil handling tool.
Step 3
Step 4
Step 5
Step 6
VCM insert
4. The specimen material is filled. The mass of material to be filled depends on the desired sample geometry, i.e. the specimen diameter as well as the desired specimen thickness (approx. 0,1‑5 grams).
5. The circular top separation foil is placed on the top of the filled specimen material. Subsequently, the piston is inserted. It is very important that the piston is pushed down slowly.
6.Assembly of the insert is complete.
VCM Insert assembling and filling procedure
Perfect results step by step
Accurate assembly of various inserts in the VCM process is vital for consistent, flawless samples. Watch the videos below for a visual guide on assembling a D25 Disc Insert for a 25mm sample and a D20 Disc Insert for a 20mm sample.
Assembling 2mm Disc Insert
Perfect for implants.
The downsizing of the VCM Insert required changes in the handling. The use of separation foils at the lateral surfaces was not feasible anymore. The lateral foil is replaced by a PTFE Tube insert. Moreover, the miniaturization also required new methods for the foil handling and the filling of the VCM Chamber. Therefore, a funnel and a paper clip were added as new components to the 2 mm Insert.
The assembling of the 2mm VCM Disc Insert starts with the insertion of the tube into the VCM Chamber as shown below. Afterwards, the unit of chamber and tube are joined with the base plate. Please be careful, the small dimensions are prone to deformation and the 2 mm protrusion of the base plate could be damaged. Join the protrusion with the tube and move both parts together and press the tube from the top down
Join tube and protrusion of base plate
Combine base plate and chamber
In the next step, the lower separation foil has to be inserted into the tube as shown below. The separation foil has a diameter of 2 mm. For larger VCM Tools, vacuum suction pens are used to place the foils, however at this small dimensions the foil handling with pens is not convient. It is recommended to use the adhesion of the foil to your finger tip. Press with your finger on the foil, the adhesion between your finger and the foil will be sufficient to lift up the foil and to place it on the upper opening of the tube. The foils needs to flat clinging on the protrusion of the baseplate, use the piston to move the foil down. Remove the pistons and check by visual inspection if the foil went down correctly and covers the protrusion
Insert foil into tube
insert
The next step is to prepare the VCM Insert for the filling. At smaller dimensions the handling become tricky. We have designed a funnel that smoothly fits on the tube in order to facilitate the filling procedure. Place the funnel on top of the tube and push it down smoothly so that it aligns with the upper surface of the tube.
Subsequently, the powder can be filled from top as shown below. In many cases, powders do have poor flowability and are not free flowing. In such cases use a paperclip to move the powder into the tube. The if you are aiming a defined sample height, this procedure can be done on a scale. Powder may stick to the so that weighing without funnel may lead to more reproducible results. Gentle tilting of the funnel is recommended for the removal. If long samples are desired the compaction during the filling increased the maximum filling weight. Remove the funnel from the tube and use the piston to compact the sample material within the tube. After the desired amount of the powder is filled, the funnel can be removed.
use paperclip to move powder
remove funnel
In the next step the top separation foil needs to be inserted. Use the finger tip adhesion to the foil to place the foil on top of the tube. Apply slight pressure on the top to press the foil inside the tube. Make sure that the top foil is almost parallel to the top surface of the tube. Insert the piston from the top and press the foil down and compact the sample.
Insert foil into tube
insert
The insert is now ready for the operation according to the manual of the VCM Essential and VCM Tools. It is strongly recommended to use the low-pressure lid as shown below.
How to use separation foils
Easy as a piece of cake.
VCM Technology is designed to make your daily lab routines as smooth as possible. For this purpose, separation foils are multiple times reusable and easy to peel off from the sample, ensuring the best output after the operation.
One pack consists of 100 sets of separation foils. Thanks to the precise cut of the foils, the best possible results are guaranteed.
After checking that lateral surface is wholly pushed down before the baseplate and the chamber is put together, place the circular bottom separation foil on the base plate. This should be carried out with the supplied foil handling tool illustrated below. Make sure that the pick-up pad is clean before you use it; otherwise, the foils might fall.
At smaller dimensions the foil handling becomes tricky. MeltPrep provides foil handling pins for VCM Disc Insert sizes smaller than 10 mm. The pin is designed to align the lateral separation in the VCM Chamber. It has an ergonomic handle, and its cylinder has a tight fit with the VCM Chamber. A chamfer at the protrusion enables easy insertion and protects the foils from damages.
How to insert your lateral separation foils:
A. Roll in the separation foil and put it into VCM chamber. One can also fold the foil two times for easier insertion. Be careful when folding the foils, one must not leave kinks in the foil.
B. After insertion, the foils should protrude at both ends of the VCM Chamber evenly.
C. Take the foil alignment pin that fits your VCM Insert dimension and push the pin carefully through the VCM Chamber. Slight rotation of the alignment pin can help to align the foil.
D. The alignment pin should protrude at the opposite opening of the VCM Chamber. Make sure that the foils protrude uniformly at the openings.
E. Release the alignment pin from the VCM Chamber. Rotating the pin while slightly pulling is suggested during the release of the pin. Your foil is now perfectly aligned in the VCM Chamber and you are ready to continue with your sample preparation.
