Optomechanical Design and Systems Integration
We excel at creating complete optical systems that balance optics, mechanical design, and environmental modeling. Every assembly is engineered for performance, reliability, and alignment across a diverse range of applications.
Our optical design solutions include:
- Lens layout & thermal management for lenses and assemblies
- Mechanical stress & tolerance analysis
- Optical alignment and stray-light control
- Design tools such as Zemax, Code V and FRED are utilized for precise simulation
- Vibration and temperature modeling for mission-critical durability
- In-house testing and qualification to verify system performance
By combining optical design with mechanical engineering, troubleshooting occurs early in the design process, saving cost and reducing risk.
Experts in IR and Thermal Cameras
Clear Align is recognized for its unique ability to design and build advanced IR and thermal camera systems. Our optical engineers and mechanical engineering specialists develop optical assemblies and innovative hardware that meet the strictest SWaP requirements.
We have designed and qualified:
- MWIR and LWIR zoom and fixed-field optical systems
- Helmet-mounted, direct view wide-field IR displays
- Multispectral & hyperspectral optics
- Rugged EO/IR assemblies for airborne and ground missions
- Laser rangefinders and receiver modules
Our integration of optical components, lenses, and systems ensure optimal performance in fielded systems.
Laser & Optical Subsystems
Beyond imaging, we design optical systems for laser devices and subsystems. With in-house manufacturing and coating expertise, we create lenses that withstand extreme conditions.
Capabilities include:
- Laser-induced damage threshold (LIDT) analysis and testing
- Free-space optical communication devices
- Interferometers, illuminators, and spectroscopy lenses
- Space-qualified optical components and subassemblies
Every subsystem undergoes detailed analysis, from material characterization to system-level verification, ensuring readiness for deployment.
Design for Manufacture (DFM)
Unlike design-only firms, Clear Align incorporates DFM into all projects and has an optical systems engineer supporting each program. As an optical factory with in-house manufacturing, we can troubleshoot issues during the design process to guarantee a smooth transition from prototype to volume production.
Every optical design undergoes peer-reviewed analysis including stray-light modeling and tolerance verification. This thorough process allows us to deliver cost-effective optical solutions without compromising performance.
Advanced Design Tools and Consulting Services Powered with Precision
Our optical design software (Zemax, FRED, and Code V) enables us to simulate complex optical systems and create optical design solutions tailored to many industries. We provide consulting services that span:
- Concept development and requirements specification
- Alternative design studies and system trade-offs
- Prototype fabrication and first-article validation
- Final qualification for field deployment
By leveraging our extensive expertise and design tools, we can address almost any optical problem—from illumination design to multispectral imaging.
Precision Performance Difference
As optical systems get smaller, the demand for higher-level precision optics grows. Clear Align offers specialized tooling and centering capability to support direct view systems, high-resolution cameras, and precision sensors.
Every project benefits from our special problem solving ability, extensive knowledge, and focus on innovation—ensuring the best solution.
Clear Align is your Optical Engineering Partner for Precision Optical Technologies
From custom optics and glass lense manufacturing to advanced optical systems, Clear Align delivers world-class design services and optical solutions. Our company is trusted worldwide to create precision optical systems and ruggedized assemblies that protect lives, enhance imaging, and deliver real-world performance.