Our Process
Proof of Concept
In this initial stage, we work with you to finalize the specifications and perform a limited first order trade-off study. The outcomes of this study will confirm that physics is on our side and that the desired system can be built. In this study, we also produce several possible optical layouts, as well as potential trade-offs. We review these with you to determine the best path for success. This results in a final, achievable specification document.
Preliminary Design Review (PDR)
Next, we produce the full optical design and a limited opto-mechanical design. Our optimized optical design process accounts for many aspects, including:
performance specifications,
volume requirements,
lens manufacturability,
glass types,
athermalization requirements,
allowable compensators, and
assembly requirements.
Our design optimization occurs in a loop with the tolerance analysis to ensure that the design is manufacturable.
A key component of our design and tolerance processes is consideration - very early in the design process - of not just the manufacturing errors of the lenses, but also possible assembly errors, which accounts for errors in the metal manufacturing process and during the assembly process. In the beginning of our tolerance analysis process, we perform sensitivity studies to determine which design aspects are the most susceptible to errors and address them, as needed.
We take the information that we learned from the tolerancing process to conduct Monte Carlo testing with all possible manufacturing and assembly tolerances sampled to produce a set of simulated as-built optical systems. The performance of these Monte Carlo tests gives us a performance estimation of the final manufactured system.
From the tolerance analysis we derive the preliminary assembly, alignment, and testing procedures; which become requirements for our opto-mechancial engineers and designers.
Depending on the requirements, at this point, we may perform the first order stray light ghosting analysis. We complete the full stray light analysis after the final mechanical design is complete.
This phase includes a preliminary opto-mechanical design to show the general scheme for holding the optics and the drawing package of the custom optical components.
This phase ends with a design review, where you determine if you would like us to order the custom optical components from our trusted suppliers.
Critical Design Review (CDR)
This phase produces the final opto-mechanical design, final bill of materials; finalized procedures for assembly, alignment, and testing; and the completed mechanical models with associated drawing package ready for procurement.
During the mechanical design, our engineers consider the performance specifications, tolerance requirements, movement needs, surface finish, and volume and weight requirements; also stress and environmental conditions including vibration, shock, and thermal.
Depending on program requirements, we perform varying levels of finite element analysis (FEA) which, along with other engineering calculations, will inform the mechanical design in varying areas. Some examples include the size and shape of a flexure design and demonstrating an optimal adhesive over the full thermal range.
During the final stages of the mechanical design, we may complete a full stray light analysis using the software tool, FRED.
Our opto-mechanical design process includes completing assembly and test procedures, as well as tooling design. Specific tooling may be necessary to align components or to permit holding of a component while adhesive cures.
The CDR phase ends with a design review, where you determine if you would like us to order the custom mechanical components.
Procurement
We work with trusted suppliers of custom precision components. These suppliers are typically USA-based and provide material certifications to ensure quality and compliance. We perform full article inspection, cleaning, and kitting on all supplier-furnished materials in preparation for the build and test phase.
Build & Test
In the final phase, we build and test the final optical systems. After receiving the components, we follow our developed unique procedures to assemble and align the system. During the alignment process we typically use compensators to adjust for manufacturing errors to achieve the best possible optical performance.
The final step is the optical performance testing and comparison to the optical model, as needed, possibly including additional environmental testing such as vibration, thermal, shock, etc.
Delivery & Lessons Learned
Finally, we carefully pack and ship the final compliant system(s) to you.
We then request your feedback and apply your responses in our internal post-project “Lessons Learned” meeting. This allows us to continuously improve our processes and our customer service.