Custom lens assemblies can perform well in early builds and have issues come up when production planning begins and the realities of time, labor, and repeatability come into play. This can lead to longer timelines and drive up costs.
Design for manufacturability (DFM) ensures that a design can be produced consistently and affordably in production. At OSE Optics, we focus on closing that gap so our clients can move from one successful build to a reliable production run without unnecessary redesigns.
The Role of Standardization in Component Optimization
When a system is custom, it can be tempting to design each component from scratch. In early development, that flexibility can help solve specific challenges. In production, however, too many unique parts can at times slow procurement and complicate assembly, impacting costs and the final result.
There are a number of ways to consider where standardization can support component optimization while managing costs. Selecting materials that are easier to source, adjusting dimensions to match common tooling, and making other minor changes at this stage can reduce lead times and cost per unit once volumes increase.
Prototyping and Development: How Tolerances Fit In
Prototyping can involve balancing innovation with meeting strict tolerance requirements. It also requires reviewing tolerance stacks with production in mind to anticipate potential issues later in the process. Defining key parameters clearly and measuring them consistently during pilot builds allows teams to identify trends before full production begins, which helps prevent costly surprises down the line.
Using Active Alignment to Improve Performance
Tying the alignment strategy directly to the mechanical design ensures that optical performance remains stable across varying environmental conditions and production scales. Compared to passive assembly, which relies on the physical precision of machined parts to hold lenses in place, Active Alignment (AA) utilizes sensor feedback to position components based on optical output.
While active alignment can involve a higher initial cost, it can enhance image quality and compensate for slight variances in lens barrels or other components. It can be critical in complex or high-precision applications, helping avoid the need for disassembling and costly rework.
The OSE Advantage: Bridging Engineering and Impact
At OSE Optics, we have experience bridging design and manufacturability to achieve high-performance, cost-effective optical assemblies. We can work with a range of project types, including:
- Prototyping
- Low-volume custom builds
- High-volume production
Our DFM approach focuses on component selection, tolerances, alignment, and other aspects of design and engineering that contribute to cost-effectiveness in the final assembly while maximizing performance in demanding environments.
Contact OSE Optics to Learn More
While a successful prototype is an important milestone, it’s just the start. Cost-effective processes for custom optical assemblies demand consistency, efficiency, and engineering expertise at each stage of the process. OSE Optics can move your team from proof of concept to production with confidence. By integrating design for manufacturability into custom lens assemblies from the onset, we protect optical performance while supporting a smoother path to market.
Contact OSE Optics or request a quote to get started.