Automation & Systems Engineering
Optoelectronics Engineering
Tunable laser assembly and characterization
The Challenge
The client was assembling a tunable laser using a highly labor-intensive alignment process that required the simultaneous optimization of more than ten degrees of freedom.
The workflow was entirely manual and depended on tooling that was difficult to modify or update.
Documentation was limited, and there was little quantitative insight into alignment sensitivities. .
The process was very sensitive to adhesive shrinkage, which significantly reduced yield-even after successful initial alignment.
The Approach
Developed deep understanding of the device and existing assembly process, in order to maximize impact while reducing demands on client’s team time
Created an analytical model of the tunable laser, and developed an understanding of alignment tolerance magnitudes.
Divided the alignment process into multiple characterization and alignment subprocesses.
Devised suitable alignment approaches for each step (e.g. passive, machine vision assisted, actively aligned) ,through tolerance modeling.
Characterized subcomponents to measure critical properties and relax alignment tolerances.
Developed initial concepts for all the characterization and alignment stations, and evaluated expected performance tradeoffs.
The Work
We designed multiple characterization and alignment and stations to complete the full assembly process.
Given the aggressive schedule, we relied as much as possible on off-the-shelf components, and focused our design efforts on a small number of critical custom components.
We procured, assembled, programmed, and developed processes for all the stations.
We tested and gathered data on all characterization and aling and attach steps.
We delivered the stations to our client, and trained them to use them.
The Impact
We massively decreased alignment and assembly cycle time, while drastically improving yield.
We contributed design improvements to components and laser system design
Added metrology and characterization functions to further improve component and system understanding and improve yield
Through modeling Achieved deeper understanding of components and system performance, forging path for future improvements
We implemented the stations and developed process to assemble tunable laser in under 6 months, enabling our client to reduce time-to-market and increase market penetration and share.