Ingeneric (Germany)

Beam-shaping is essential for any kind of laser application. Assembly technologies for beam-shaping subassemblies are subject to intense research and development activities and their technical feasibility has been proven in recent years while economic viability requires more efficient engineering tools for process planning and production ramp up of complex assembly tasks for micro-optical systems. The work presented in this paper aims for significant reduction of process development and production ramp up times for the automated assembly of micro-optical subassemblies for beam-collimation and beam-tilting. The approach proposed bridges the gap between the product development phase and the realization of automation control through integration of established software tools such as optics simulation and CAD modeling as well as through introduction of novel software tools and methods to efficiently describe active alignment strategies. The focus of the paper is put on the methodological approach regarding the engineering of assembly processes for beam-shaping micro-optics and the formal representation of assembly objectives similar to representation in mechanical assemblies. Main topic of the paper is the engineering methodology for active alignment processes based on the classification of optical functions for beam-shaping optics and corresponding standardized measurement setups including adaptable alignment algorithms. The concepts are applied to industrial use-cases: (1) integrated collimation module for fast- and slow-axis and (2) beam-tilting subassembly consisting of a fast-axis collimator and micro-lens array. The paper concludes with an overview of current limitations as well as an outlook on the next development steps considering adhesive bonding processes.

Efficient and reliable optical design requires knowledge of the production chain, the materials used, and the environmental circumstances in the field of operation. This is realized in the comprehensive modelling approach consisting of three steps: • Design for manufacturing, i.e. the model must be adjusted to the process chain. Knowledge of design rules is required. • Robust design, i.e. optimization of the functional design with the objective of a compensation of the tolerance influences on the system’s performance. Knowledge of the tolerances of the individual process steps is required. • Reliable design with respect to environmental and operational effects, respectively. Coupling of an optical and mechanical simulation tool is required to form the optical simulation environment. The availability of process knowledge such as e.g. design rules and manufacturing tolerances is ensured by coupling of the optical simulation environment with a process knowledge database. Integration of measured surface data in this simulation environment enables a realistic simulation and analysis of real, manufactured optics. This approach allows e.g. for the evaluation of replication methods such as precision molding or injection molding against high-precision manufacturing methods, e.g. diamond turning.

Abstract Die neue Technologie des Präzisionsblankpressens ermöglicht hohe Präzision trotz niedriger Kosten in der Herstellung anspruchsvoller optischer Komponenten. Diese Fertigungstechnologie ist leistungsfähig genug, um verschiedenste komplexe Geometrien wie beispielsweise Asphären, Arrays oder diffraktive Optiken herzustellen und kostenaufwändige herkömmliche Verfahren wie Schleifen und Polieren zu substituieren. Um die Fähigkeiten der Technologie optimal ausnutzen zu können, wurde in den letzten Jahren eine entsprechende Befähigung der gesamten dazugehörigen Lieferkette von der Rohmaterialherstellung über die Formwerkzeugfertigung bis hin zur Messtechnik vorangetrieben.