Optics · Precision Fixture · DFMA
Kinematic Optics Jig — Micron-Repeatable Assembly
A compact kinematic fixture for assembling and aligning a short optical train. The jig combines a three-point kinematic interface with fine adjusters and positive hard-stops to deliver reliable re-locate & clamp behaviour with minimal induced stress on fragile optics.
*Indicative; verified on gauge blocks & test coupons.
Brief
Create a robust, repeatable assembly fixture for a compact optical path: couple lens barrel, fold prism and detector package while maintaining centration, tip/tilt and focus without adhesive-induced shift.
Design approach
- Kinematic base (cone–vee–flat) to remove over-constraint and ensure deterministic re-location.
- Decoupled clamping with flexure-biased pads to minimise part distortion during cure.
- Fine adjustment via differential screws & micrometers for tip/tilt/focus; positive stops for datum capture.
- DFMA: modular sub-plates, common fasteners, dowel-pinned repeatable set-ups.
Outcome
- Rapid load—align—cure workflow with clear operator cues.
- Measured repeatability in the low-micron range on pilot builds.
- Interchangeable nests for variant optics without re-qualifying the whole tool.
- Cleanroom-compatible finishes and debris-resistant enclosure of moving parts.
Mechanical optics thinking
Three orthogonal adjusters provide predictable motion about the optical axis.
Material pairing and short load paths reduce drift during adhesive cure and temperature swings.
Sight ports & flat reference faces for autocollimator or camera-based alignment.
Guarded screws, thumbsafe knurls, and clear torque order etched onto the plate.
Gallery
Key technical details
- Interfaces: Cone–Vee–Flat kinematic, dowel-pinned sub-plates
- Adjustment: Differential screws, micrometers, hard-stops, preload springs
- Materials: Tooling aluminium & stainless (passivated), low-outgassing grease
- Process: Align on live image/autocollimator, capture datums, dispense & cure