Our case studies demonstrate how we help our customers to solve optical challenges.

CASE STUDY 1:

LARGE DIAMETER LENSES

The Vision Engineering Lynx microscope requires a large (160mm) diameter lens of high quality including high surface quality (40-10).

  • Initial rejection rates for the lens were around 30%
  • The resulting shortage of available lenses caused a strain on production
  • The lens rejection rate also pushed up the build cost.

A technical team was set up to address this production issue. Each stage of the production process was assessed and the end result was that a far more efficient procedure for large lens production was developed. This same procedure is now standard for all large lens projects.

MICRO

CASE STUDY 2:

LARGE ASPHERICAL LENS FOR A HEAD-UP DISPLAY (HUD) SYSTEM

A German car manufacturer required aspherical plastic lenses for an auto-HUD system. Our expertise and familiarity with this type of application meant we were able to make recommendations on both the material being used and the surface quality required.  These changes provided a significant improvement to the image quality and contributed to the manufacture of a world class auto-HUD system.

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CASE STUDY 3:

COST REDUCTION OF A TURNKEY MULTI-PRISM ASSEMBLY

The requirement involved an optical system comprising filters and prisms, and presented the following challenges:

  • The optical components needed to be manufactured to a tight tolerance, with durability a key performance requirement
  • The lens rejection rate also pushed up the build cost.

Working from the existing optical set up and application, we developed a turnkey solution that essentially combined the various optical components into one unit.  The result was a more durable system, a more reliable production process, less polished surfaces and AR coatings, and ultimately a dramatic reduction in the build cost.

prism-1

CASE STUDY 4:

USING OPTICAL COMBINERS TO REDUCE PRODUCTION COSTS

Innovative design and optical expertise - a winning combination

Laser welding machines are becoming more and more poplar due to the many advantages they have over traditional cutting and welding machines. However, the growth potential within this field has proved extremely attractive to manufacturers looking for new opportunities.  This in turn has created a very competitive arena with very little differentiation between products.

When considering the purchase of a welding machine customers are looking for equipment that will create strong, visually perfect seams, even in instances where the small size of components mean that magnification is required during the welding process.

In order to provide welding machines with this level of precision manufacturing a quality product is paramount. Yet to be successful in such a crowded market, manufacturers need to be price sensitive in order to stand out from the comparable products out there.

The difficulty is to maintain quality and healthy profit margins at the same time as lowering the price to the customer. This was the dilemma presented to the team at Vision Optics by a manufacturer producing laser welding equipment.

In the current laser welders available on the market individual laser protection filters and separate laser mirrors are integrated into the head viewer to deflect the laser beam away from the operator’s eyes.

Laser welding equipment
The Vision Optics welding system with combiner optics

To meet the client’s brief the experts at Vision Optics needed to provide a solution that would streamline the optical configuration without affecting the clarity of the image seen by the operator.

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The projected image seen using the Vision Optics head viewer

To this end the optical team re-imagined the present design and created a high quality optical combiner. The introduction of the single combiner as a replacement for the old filter and mirror system not only meant savings of up to 35% on the optical elements of the head viewer but led to an easier manufacturing process.

Laser beam diagram

This is just one example of how the experts at Vision Optics have come up with an ingenious design to achieve a better quality product for their customers.  If you are looking an innovative optical design contact us.

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