Optical Systems Integration Design to Production

Complex Optical Systems Design, Prototyping, & Manufacturing

Clear Align offers expertise in designing, prototyping, and manufacturing advanced optical systems. Our team utilizes cutting-edge optical design software to create sophisticated optical engineering solutions. Whether you need …

• Multi-sensor surveillance systems from requirement to production
• Soldier thermal weapon sights for a unique sensor
• Dual-band third-generation FLIR lenses
• optics or components for missile subsystems
• Unmanned systems that support multi-channel payloads with multiple sensors
• Custom optical modules or tailored assemblies

Do you have an Optical Problem? We Provide Optical Solutions

We have the know-how to build advanced imaging or laser solution whether it is a single lens or system. Clear Align is focused on controlling costs while optimizing image clarity delivering environmentally rugged solutions. Our designers create systems using a disciplined, stage-gate development process to ensure reliability. We fabricate our optical lenses and metal for faster delivery.

Optical engineering plays a crucial role in solving complex optical problems, ensuring that our solutions meet the highest standards of performance and reliability.

Our structured approach ensures every critical parameter is addressed from SRR to MRR, accelerating the path to your goals. We have all the optical, mechanical, electrical, and software tools to integrate optics into your application. We provide in-house evaluation for speed.

Systems Integration Approach Optimize SWaP-C

Our focus is on the system’s solution that considers SWaP-C, Size, Weight, Power and Cost. We drive the system architecture by incorporating the US Department of Defense Architecture Framework (DoDAF) and implementing advanced systems modeling techniques, such as structured and object-oriented approaches.

This includes considering light detection, and optimizing diffraction-limited performance, to meet complex system requirements. We offer state-of-the-art solutions with well-defined stage-gated processes, minimizing risks and enhancing the reliability of your optical system.

We use a modular systems architecture for all our electronics designs to avoid component obsolescence issues.

Imaging Systems

Our optics channel photons to a detector, or an eye, focusing on quality factors such as image clarity, resolution, contrast, and distortion. Optical engineering plays a crucial role in designing high-quality imaging systems with a goal of near diffraction limited performance. Examples include optics for zoom leans, switched field of view, and fixed focal length lenses, modules for laser receivers, and relay systems.

Non-Imaging Systems

Non-imaging systems manipulate light by collecting, dispersing, or focusing it, with performance measured by throughput, field efficiency, spot size, and angular resolution. Optical engineering plays a crucial role in optimizing the performance of these non-imaging systems. Examples include illumination and systems with lasers.

Defining the Application

When embarking on the development of an optical system, the first and most crucial step is defining the application. This involves a thorough understanding of the specific operational needs and requirements of the system. Whether for imaging or non-imaging purposes, it is essential to consider the resolution, sensitivity, and throughput. Additionally, the environmental conditions in which the system will operate, including temperature, humidity, and potential exposure to shock and vibration, must be taken into account. Top designers ensure that optics meet the needs of the end-user.

Establishing System Parameters

Once you’ve identified the system requirements, you can define the primary parameters to guide the design process, ensuring your optical solution meets the specific needs of your application.

Rapid System Deployment with Current Technologies & COTS Integration

Clear Align utilizes modular solutions to quickly transition from development to production ready system. This includes analyzing optical layout, and mechanical housing, and integrating electronics equipment into our EO/IR systems.

Key activities during this phase involve:

• Requirements analysis, performance analysis, and system design.
• System integration and verification, requires that our designs incorporate lens elements and retainer rings that keep lenses aligned.

Our method enables quick validation of optical system designs, focusing on both imaging and non-imaging systems while maintaining alignment with performance requirements and application objectives.

Optical Components and Solution Forms

Optical components are the fundamental building blocks of any optical system, and their selection and design are crucial in determining the system’s overall performance. These components can be broadly classified into two categories: active and passive. Active components, such as lasers and light-emitting diodes (LEDs), are sources of light, while passive components, like lenses and mirrors, manipulate and direct the light.

Understanding the interplay between optical components and solution forms is essential for creating custom optical systems that meet specific application requirements. By carefully selecting and designing these elements, we can develop optical systems that deliver optimal performance for a wide range of applications.

Optical Layout

The layout of an optical system is typically determined by the application requirements, such as object and image distances, numerical aperture, and the wavelength of light.

 

Large Systems Capability, With Agile Team

Design Process

Several advanced software tools, such as Zemax and Code V, are available to assist in the optical layout and design process. These tools allow designers to model and simulate the behavior of optical systems, enabling them to optimize design parameters and achieve the desired performance. By leveraging these tools, we can ensure that our optical systems are precisely tailored to meet the unique requirements of each application.

Mechanical Design Considerations

The mechanical design maintains alignments. This involves selecting materials that can withstand thermal expansion, vibration, and shock. By carefully considering mechanical factors, designers can develop optical systems that are robust, reliable, and capable of delivering in a variety of conditions.

Electronics Integration

Modular Open Systems Architecture (MOSA) plays a vital role in electro-optics by enabling flexible and scalable integration. It standardizes interfaces and design, allowing easy upgrades and replacements as new technologies emerge. With MOSA, you can quickly adapt to changing mission requirements, reducing the risks of obsolescence and lowering long-term maintenance costs.

Testing

Verifying a design to requirements is key. This involves measuring various optical parameters, such as resolution and distortion. Several test methods are available, including interferometry and imaging, and the method depends on the specific parameter or requirement.

Experience Program Management

What differentiates Clear Align is our program management expertise, extending from the initial design phase to prototype development and full-rate series production.

Optical engineering plays a crucial role in managing complex optical projects, ensuring precision and efficiency throughout the process.

Advanced Environmental and Optical Testing

Environmental Stress Screening and testing equipment ensures we meet all specified requirements. This testing involves a series of evaluations of components, lenses, and complete systems based on military standards to verify the durability, reliability, and functionality of the solutions.

Clear Align offers the expertise of a large prime contractor with the agility and responsiveness of a small business partner. We bring value to our customers through integrated optical solutions.

Benefits of a Partnership

An partner offers a comprehensive approach to high-performance optical systems, from design to integration. With access to diverse materials, they select the best options for your needs, reducing time-to-market while delivering reliability.