Our client built a proof of concept model using off the shelf optomechanical and optical components. We worked very closely with them to develop system requirements to ensure the camera performed as required while meeting their cost targets.
The system required all optical and imaging components be aligned to high accuracies and to maintain alignment over thermal, vibrational and shock environments. In addition to these performance requirements, the camera was to be produced in high volumes for low cost. The client provided a ZEMAX optical model consisting of numerous “free space” optical components from which we initiated the design.
Structural and Dynamic Analysis
- Epoxy bond joint sizing
- Metering structure athermalization
- Dynamic analysis for operating environments
- Thermal stress for operating environments
- Shock analysis for operation and shipping
Alignment and Assembly
- Design for manufacturability
- Production of manufacturing drawings
- Tooling and component fabrication
- Assembly of alignment and assembly stations
- Training for use of alignment and assembly stations
Optomechanical design
- Optical metering structure
- Bonded optic mounts
- Integrated optical alignment features
- Shutter mechanism for calibration
- Materials engineering for selection of metals, epoxies and plastics
