Automation & Systems Engineering
Fiber bundle tester
The Challenge
Our client’s business pivot created an immediate need for specialized fiber characterization equipment.
No off-the-shelf equipment was available to perform unique, high-precision measurements for the rapid selection and development of fiber bundles.
The system had to be expandable to accommodate more sophisticated measurements and testing of subsystems.
The Approach
Defined a project plan that emphasized speed while preserving the ability to identify and address problems during development.
Defined an instrument architecture that minimized both technical risk and risk to devices under test.
Developed two metrology concepts, evaluated their risks and tradeoffs, and selected the lowest risk approach in consultation with the client.
Combined imaging systems built around off-the-shelf optics, stages, and optomechanical components with simple custom optomechanics where needed.
Developed a software architecture that leveraged proven modules and design patterns from prior projects, reducing development time and integration risk.
Segmented the system to enable parallel development across subsystems.
Maintained close collaboration across subsystem teams to ensure all elements would integrate and perform together as intended.
The Work
Designed a flexible optical system using mostly short-lead-time, off-the-shelf components, with only a small number of simple custom-fabricated elements. Ensured the system met the specified requirements.
Developed custom software for data acquisition, system control, and measurement processing.
Quickly selected in-stock data acquisition and imaging components, enabling straightforward integration and rapid progress.
Documented alternative approaches that could deliver higher performance but would require longer lead times, creating a path for future system upgrades.
Identified a stray-light issue during integration and rapidly implemented an effective mitigation.
Installed and aligned two systems, including an upgrade that provided additional control of the optical system’s Numerical Aperture.
The Impact
The systems enabled faster screening and qualification of fiber bundles, helping the client make development decisions more quickly.
Reduced risk to valuable devices under test by using a non-contact measurement architecture..
The systems were immediately used for additional tasks beyond the original design specification, expanding the value delivered to the client.
Thanks to their open, modular architecture, the systems provided a reusable platform for future characterization tasks, creating a foundation for more advanced measurements and continued system evolution.