Concept for a new approach to realize complex optical systems in high volume

Abstract

A groundbreaking new approach [1] for the fabrication of complex photonic systems, especially such with off-axis optics, has been invented based on planar mounting in combination with a novel folding approach. Up to now volume production of photonic systems has been optimized for on-axis lens based optical systems. Chromatic aberration limits the usage or spectral range of these systems. Applying mirrors instead of lenses may help to suppress chromatic aberrations and wavelength depending absorption. The assembly of reflective optics, often in an off-axis configuration, is a complex process. So far most tools for volume production apply stacking of components in planar technology. Off-axis systems are typically assembled by more or less manually alignment of the components, which is not in favor for mass and low cost production of these systems. The novel approach utilizers a planar substrate featuring preprocessed bending lines. A high accuracy tool for planar assembly places the components onto the substrate. Then the sides of the substrate are bent leading to a predefined three dimensional body. The off-axis optical path inside is generated automatically. This concept is not limited to rectangular shapes but can also be applied to more complex systems, for example the so called "W-configuration" for a Czerny-Turner spectrometer. First tests of the "bend and place assembly" have been performed successfully on a camera setup to prove the working principle.

Applications for a broadband NIR spectrometer with scanning mirror device

“…Different integration strategies for miniaturized MEMS based systems have been developed and investigated. Throughout this work the so-called "Place and Bend Assembly" [9,10] or the principle of "stacking of subassemblies [11] are considered as favorable options.…”

SmartSpectrometer—Embedded Optical Spectroscopy for Applications in Agriculture and Industry

“…A new concept called “place and bend assembly” [ 18 ] uses a mostly planar substrate where the components are placed by standard 2D assembly tools. Afterwards the substrate is folded along previously designed bending [ 19 ] lines and the 3D body is generated with the optical path inside. Applying this technology a first spectrometer has been realized recently ( Figure A4 ).…”

Place and bend assembly: towards production of substrates in high volume technologies

“…In order to facilitate volume production of such complex optical systems a new concept has been presented in 2017 [1]. The basic idea is to generate foldable quasi-planar substrates with integrated optical components.…”