Fusion Design develops many custom tooling solutions, often in support of volume production to reduce the number of steps needed to accomplish precision alignment between optical elements. Camera-based systems and laser-based systems often need this type of tooling. Usually, manufacturing for optical equipment relies on a significant amount of hand assembly but with tooling, the alignment can be done quickly and efficiently, saving time and money.
An automatic or semiautomatic tool can be used to line up the optics perfectly with beam or image references in the design.The tolerances of mounting surfaces and optical elements vary throughout the life of the product manufacturing operations and rapid adjustment and securing methodologies are needed to compensate for any errors. Alignment calibration for an optical assembly can correct the following kinds of errors:
Surface defects and tolerances
Material defects and tolerances
Mounting tolerances
Once the optical components are aligned, they are secured to the associated mounts, often with rapidly curing optical adhesives. In contrast to traditional manual alignment, motorized tooling can tilt and rotate the components so that the optical axis of the lens is aligned to match the reference axis of the system. This is fully automated and can be embedded in the process flow, enabling a shortened fabrication and test cycle.
Our Checklist for Capturing the Requirements for Custom Assembly and Alignment Tooling
Review, understand, and document the requirements up front
Collect all the dimensional data required (mounts, optics, fabrication tolerances, input variances)
Capture the output expectations (image / beam quality and size requirements, alignment tolerances)
Understand production volume, manufacturing environment / location, process flow
Sensitivity to distortion loads on optics
Gluing assembly procedures
Glue management for purity, storage, potting life and transfer minimization
Allowable materials to be used in cleanrooms
Kinematic design to reduce tolerance
Sensitivity to thermal expansion with allowable mitigation techniques
Familiarity with standard optical fixturing from Newport and PI
With our knowledge of design for manufacturing (DFM), we formulate solutions that are aligned with all of those parameters. Whether it is a robotic solution or a simple hand tool, we streamline the manufacturing process for rapid and repeatable part production.
Fusion Design specializes in industrial automation, custom tooling systems, process control solutions for manufacturing improvement, and motion control. Let us know if we can help you optimize manufacturing for rapid delivery of products.
