Optical systems routinely require extremely tight tolerances for optimal performance. Opto-mechanical engineers bridge the gap between optical design concepts and a realizable system by working closely with the optical designers to provide a robust, manufactured system operating as close as possible to theoretical limits. Manufacturing tolerances are provided to the optical designers, who in turn analyze the optical system. Once a design is finalized, fixturing and procedures are developed to assemble the system to the required specifications.

In optical systems, elements typically require adjustments in one or more degrees of freedom. Both automated and manual systems are commonplace in optical systems. The magnitude of these adjustments can vary from gross displacements to fine adjustments on the order of nanometers. Opto-mechanical designers must incorporate these adjustments within the space and weight constraints available, while providing a user-friendly interface to the instrument. Polaris’ engineers have a wealth of experience incorporating commercial off-the-shelf products into our systems as well as designing custom micro-motion components.

Polaris opto-mechanical engineers utilize SolidWorks 3-D modeling software to create designs. Harsh operating environments often require further analysis to ensure a robust optical system. Polaris routinely designs MWIR and LWIR systems that require cooling to cryogenic temperatures. Additionally, many systems must be designed to handle shock and vibration loads encountered on platforms such as armored vehicles, UAVs and robotic systems. CosmosWorks finite element software provides a means to analyze the displacements, stresses and natural frequencies induced in an optical system in such environments. This is particularly critical in polarimetric systems, where stress levels well below the yield stress can cause significant birefringence, greatly reducing system accuracy.

The opto-mechanical design expertise at Polaris allows for a smooth procession from theory to optical design to completed hardware in a timely, cost-effective manner.