In the modern-day high-tech landscape, many products are becoming increasingly dependent on optics for core functionality. Yet, for organizations beyond the optics industry, developing in-house optical abilities can be time-consuming as well as resource intensive.
For those without specialized knowledge, mastering optical physics, design, component integration, and best practices in optical assembly can be a daunting challenge, potentially jeopardizing time-to-market, budget, and customer experience.
This complexity tends to arise because to optics, as a discipline, works in a unique way compared to wider domains such as electronics, mechanical engineering, or software.
As such, creating an in-house optical system requires a large amount of investment in terms of both infrastructure and expertise, which may not be reusable for other business operations. As such, for many businesses, partnering with an external optical specialist becomes a more viable and strategic option.
In this article, Zygo explores situations wherein outsourcing optical device manufacturing may be the best course of action and offers guidance on how to select the right partner.
When to Consider an External Partner for Optical Solutions
Working with an optical specialist can result in more efficient and effective product development in many situations. For instance, if optics are just a small part of a larger system, like when the core product is primarily reliant on software, algorithms, or complex systems, the optical part may represent just a minor fraction of the overall value.
In these cases, outsourcing could be a strategic choice that enables a company to hone in on its primary competencies. Similarly, when speed-to-market is crucial, hiring an internal optics team may be time-consuming while partnering with an experienced external specialist can considerably speed up the development process.
In situations where market growth is unknown, a significant investment in optical infrastructure may be impractical. Collaborating with an external partner gives companies the flexibility to scale production according to demand, avoiding the high upfront costs of creating in-house capabilities.
Similarly, if on rare occasions a product requires optical expertise, maintaining a dedicated optics team may be ineffective. External partners can also be great for smaller manufacturing values, as reduced production runs are often more economical if outsourced simply due to the economies of scale external partners can provide.
Even when in-house team members have an understanding of optical design, translating a sophisticated design into a manufacturable product can be quite tricky.
As seen below, a manufacturing partner with hands-on experience can help to bridge the gap between design and production, guaranteeing that the end product meets both practical and technical requirements.
In any of these situations, a trusted partner with optical systems expertise can produce excellent results while enabling businesses to focus on their core product and operations
Image Credit: Zygo Corporation
Defining a Productive Partnership
The term "partnership" is used a lot throughout industry, however, it tends to be used incorrectly.
True partnerships between clients and suppliers extend beyond transactional relationships and involve a profound level of collaboration that can considerably improve the product development process. Effective collaborative supplier partners serve as an extension of the client’s engineering staff, and take ownership of their client's timeline, budget, and goals.
Unfortunately, numerous companies regard partnership as a potential "lock-in" in the later stages of development. However, when the relationship is built upon open communication and mutual trust, these concerns can be reduced.
A good partnership enables clear expectations, robust program management, and a shared commitment to reaching the best possible results for both parties.
Building Trust with Your Optical Partner
Trust is imperative to any successful collaboration. Without trust, even the most technically capable supplier might struggle with delivery. When assessing potential partners, two important questions need to be considered.
First, you must ask yourself if you can trust your chosen partner to act in your best interest. Trust is built on the foundation of transparency and honesty. A reliable supplier will keep you informed of any difficulties as they arise and work proactively to resolve them before they escalate. This level of trust ensures a productive, long-term relationship.
Second, does your chosen partner have the right level of expertise and competence to deliver on your needs? Expertise is essential when navigating the complexities of optics. Your partner should be able to demonstrate the skills and experience needed to address the specific challenges of your project.
A reliable partner will not only be able to satisfy your immediate requests, but they will also be adept at designing systems that are neither over- nor under-engineered, ensuring cost-efficiency and performance.
Lastly, does your supplier have the capacity to support your project? Trust and expertise mean nothing if the partner you have chosen lacks the bandwidth to deliver on time. Without enough capacity, even the most promising collaboration can face delays, putting your ability to reach the market ahead of competitors at risk.
A strong partner aligns resources with your project timeline, ensuring both accuracy and on-time delivery.
Ensuring Effective Collaboration
Effective collaboration demands more than simply going through a process; it involves consistent communication, transparency, and adaptability.
When assessing an optical partner, ask for case studies or testimonials that display how they collaborated on previous projects. Moreover, see whether they have a structured development process that consists of regular milestones and direct engagement with their clients’ team.
The optimal partner will offer comprehensive schedules, share progress regularly with collaborating engineers, and handle unforeseen difficulties with open, solution-focused communication. This proactive approach enables a positive working relationship and makes sure that any hurdles are efficiently resolved.
Importance of Robust Processes and Program Management
Managing the developmental process of optical systems requires robust program management. Suppliers should adhere to a properly defined process that takes the project from concept to production. This process should be communicated in a clear manner to clients, with crucial milestones highlighted and rigorously tracked.
Consistent updates and program reviews help to ensure that all parties are aligned and that any deviations from the plan can be quickly resolved. Suppliers with properly established processes will give you the upmost confidence in the overall success of your project.
Here is a Typical 6 Step Workflow:
STEP 1 - Specification Development. The supplier should develop first order candidate designs and evaluate specifications in close collaboration with the customer to identify the project’s technical and commercial feasibility. The supplier should pinpoint key cost and performance drivers and suggest alternatives where appropriate.
STEP 2 - Preliminary Design Review (PDR). A preliminary optical design issued together with a mechanical model (including preliminary FEA where appropriate) with approximated performance should be suggested relative to specification. The overall mission should always be to develop the design to the point that long lead items can be ordered.
STEP 3 - Critical Design Review. Optical design with tolerances displaying yield relative to specifications should be finalized. Final mechanical model, FEA analysis, optical tolerancing, and print package. The aim is to release all components for fabrication.
STEP 4 – Prototype. Build and test prototype units. Update prints to enhance manufacturability. Carry out any required qualification tests and identify production process enhancements.
STEP 5 - Low-Rate Initial Production (LRIP). Use and refine improved designs and processes. Refine prints if further manufacturability problems are discovered. Put designs under full production design control.
STEP 6 – Production. Steady-state production with quality control systems in place. Use automated electronic data management for higher volume programs.
Image Credit: Zygo Corporation
Verifying Capabilities and Expertise
When choosing a supplier, it is important to sit down and carefully evaluate its abilities. Technical expertise is critical. Understanding the depth of knowledge inside their team, such as the number of engineers, designers, and technicians with relevant experience, can provide insights of a supplier’s ability to handle complicated projects.
Similarly, it’s helpful to understand whether suppliers have the resources and flexibility to manage surges in workflows to ensure that your project doesn’t run into any delays.
Financial stability also plays a significant role in a supplier’s reliability. A financially sound supplier is better positioned to maintain consistent quality and manage supply chain fluctuations, especially for critical materials like glass and metal, which are vital in optical component manufacturing.
Also key is the supplier’s ability to move smoothly from design to manufacturing phases. A well-established supplier will incorporate its production team soon in the design process, ensuring prototypes transition to mass production seamlessly without any unnecessary delays. Validation and testing abilities are also critical, especially for projects with precise optical needs.
A strong supplier will have custom test approaches to verify crucial specifications, which is particularly advantageous for high-precision use cases, including those involving extreme ultraviolet (EUV) systems or advanced optical alignment. This level of comprehensive validation can help make sure that optical parts accord with strict performance standards.
A company such as Zygo, a leader in electro-optics parts and assembly, exemplifies the degree of technical expertise and facility sophistication crucial for high-precision optical manufacturing. Zygo's engineering abilities are underscored by ISO 5 (Class 100) and ISO 6 (Class 1000) clean rooms, which enable production in controlled environments crucial for sensitive optical parts.
Their dedicated metrology area provides a series of sophisticated testing tools, like interferometric surface error and roughness measurement, wavefront and lens alignment tests, and MTF testing through slanted edge approaches, ensuring parts accord with stringent optical and mechanical standards alike.
Zygo’s ultra-precision assembly expertise also includes advanced alignment techniques, such as active alignment for < 2 µm TIR and sub-micron tolerances with custom processes.
This approach is crucial for applications requiring λ/40 surface figure precision and roughness control over many special bands, showcasing Zygo's ability to support complex, high-tolerance designs and transitions from prototype to production seamlessly.
Conclusion
Being a successful optical device manufacturer, especially when you lack an in-depth level of internal expertise, is, in fact, entirely feasible with the right external partner.
By prioritizing trust, collaboration, and robust processes, you can leverage the knowledge and infrastructure of a specialist to meet your optical needs effectively, without the burden of building these capabilities in-house.
With careful consideration of your partner’s expertise and approach, you can ensure the successful development of your optical systems, allowing you to focus on what you do best.
This information has been sourced, reviewed and adapted from materials provided by Zygo Corporation.
For more information on this source, please visit Zygo Corporation.