Partnering for Performance
We work side-by-side with our clients to solve their toughest problems.
These case studies show how collaboration and innovation come together to produce measurable outcomes.
Identifying a Problem Lens before Fabrication
Our client was awarded a contract to build 100+ LWIR optic modules, but did not have experience with the alignment and testing of optical assemblies. They subcontracted Optikos to assemble, align, and test the LWIR optic modules. Optikos reviewed the documentation package and determined that the customer had ordered sets of alternate lenses that could not meet the required image quality and advised our customer to change the order. Fortunately, a small number of lenses had been fabricated at this time, so a costly mistake was avoided. Optikos developed a series of fixtures and alignment techniques for bonding lens elements and adjusting mirror angles to meet the stringent line-of-sight requirements. Optikos achieved 100% yield and delivered the assembled units on-time...
Benchmarking for Process and Cost Improvements
Our client wanted to benchmark their internal production costs against industry competitors. Optikos was provided with a set of desired manufacturing optical tolerances and an optical model of a baseline lens system. Optikos used the optical model and the tolerances to generate tolerance lens drawings of the optical elements, and sent out a request for quote to a variety of lens manufacturers. The resulting quotes were compiled and analyzed to highlight areas of competitiveness and areas for improvement. The manufacturing cost data and recommendations were provided to our client, who was able to make strategic business decisions regarding process and cost improvements for a more competitive product. Have a project in mind? Get started here.
Cardioport Prototype for Open-Heart Surgery
Dr. del Nido and Dr. Vasilyev at Boston Children’s Hospital developed a novel, prototype cardioport for beating heart, image-guided intracardiac surgery for pediatric patients. The device incorporated an endoscope and a prototype viewing window, but the design of the prototype window distorted a portion of the endoscope’s field of view critical to the surgical procedure. The Technology and Innovation Development Office of Children’s Hospital Boston selected Optikos to assist in the redesign and development of the cardioport imaging window. Optikos was provided mechanical models and optical specifications of the existing prototype, and we used this data to develop an optical model of the imaging system. The optical challenge was not unlike that of designing an aerodynamic window in which...
Modifying Design for Accurate Barcode Scanning
Our client’s new product was released to manufacturing and the initial builds did not perform satisfactorily. Optikos reviewed the product specification and design. We inspected vendor supplied piece parts and discovered that the radiometry of the design and the optical performance were insufficient to ensure adequate performance over the entire set of system requirements. We modeled the design, reviewed the specification requirements, and made design changes that ensured the product would satisfy the desired performance specifications. We also inspected all relevant piece parts and uncovered errors in the lens tooling and worked with the supplier to implement the new design and correct the tooling errors. The customer’s product development effort is brought back on track and its performance and...
Heads-Up Display Testing with Multi-Sensor Fusion
Our client designed and fabricated multi-spectral heads-up data fusion displays for visual guidance of aircraft. Unfortunately, they did not have the in-house capability for testing the assembled unit. Optikos reviewed the technical specification and quickly assembled the fixturing and metrology apparatus to ensure the unit performance (MTF) over its full field of view, pupil diameters, and positions. The customer was able to demonstrate compliance with all design specifications. Have a project in mind? Get started here.
