Micro optics assembly for ultimate precision

These cameras ensure safety inside and outside of the car. These micro cameras can’t be built without micro optics. Micro optics are the optical parts of the camera that are used to grab an image. The high quality images can only be obtained when these parts are clean and assembled with extremely high accuracy. As the micro optics market grows quickly, demand for smart production processes grows along. These processes result in higher volume output and better optics quality.

Micro optics and their requirements

Optics are hard. The market is very dynamic. They often face sudden changing demands and stringent quality requirements. This type of market calls for solutions that are flexible and adaptable to the future. Typically, micro production solutions must be capable of producing high mix, high volume. All of this also has to be done with very high accuracy, whilst providing a clean environment.

Developing special systems for specific challenge

We want our customers to manufacture their micro optic products in the best possible quality. Only then they can stay ahead of the competition. To do this, we are required to develop special optical systems. Systems that function as the core of the overall positioning system. This special system uses negative perspective that allows us to see two components lying on top of each other. In one shot. Even when components have exactly the same dimensions. With the image, we then generate using the optical system, we calculate the relative offset between the two components. This is used to align them with great precision. If the components move, we apply the appropriate correction to both equally.

In a subsequent step, we can then place the components extremely accurately on (or in) each other. A custom made linear motor positions the parts relative to each other with an accuracy smaller than 1 µm (micron).

Modular production line for multiple processes

We use our modular automation platforms as the basis for these production lines. On top of this platform, multiple process units take care of the required process steps. Our platforms are very suitable for this type of manufacturing, because of it’s pre-positioning accuracy of 20 µm. With fine positioning making even sub-micron accuracy possible. We achieve such accuracy since positioning is unaffected by temperature and vibration variations or differences. These are under tight control within the platform. The built-in clean air environment allows for clean assembly of delicate product parts.

Within this project, we vision check after every assembly step. We analyze the product for errors, contamination and scratches. Whenever the machine discovers such an error, the product is taken out of the production process. Keeping in only the best production quality.

The modular platform means that multiple platforms can be connected to each other. Another unique aspect of the modularity is that process units are interchangeable. We can shuffle around with assembly steps. We can also extend platforms to enlarge the number of process steps performed on the production line. We’ve delivered well over 100 of these production lines and we’re counting. We also offer an extended SLA and make sure our customer remains as market leader with these solutions.

High volume micro optics for the future

Our approach and oversight of the whole production challenges resulted in some major advantages for our customer. Smooth collaboration on the project also made this project into a success. Our customer has gained the following advantages:

• Every 2 seconds a micro optical product comes off the production line;
• Increase in process reliability and assurance of the best possible quality product for our client’s end customers;
• High availability of the production line: easily adaptable for manufacturing of a different product type.

Participating at the Fraunhofer Project Center

As we see the process of improving the product quality of micro-optics, we have joined forces with Fraunhofer Project Center. Fraunhofer is part of the University Of Twente, one of the best technical universities in The Netherlands. They are the go-to design and production engineering institute for very complex, high-tech systems.

Our collaborations with Fraunhofer makes it possible to serve our customers with the best technology for assembling their micro-optics products.

How can we help you improve further?

Whatever your precision challenges are, we’re sure that we can offer you a fitting solution. Challenge our experts and see what IMS can do for you.