Optomechanical Design

Classify the optical, mechanical, and thermal functions in a simple optomechanical product.

Convert dimensions and tolerances between SI and US customary units.

Report calculated dimensions with appropriate units, precision, and significant figures.

Measure external, internal, depth, and step dimensions with digital calipers.

Estimate measurement uncertainty from repeated caliper readings.

Translate a product need into measurable optomechanical design requirements.

Build a requirements-verification matrix for an optomechanical assembly.

Resolve a force or displacement into orthogonal components using trigonometry.

Draw a free-body diagram for a loaded optomechanical component.

Calculate the moment of a force about a specified point.

Calculate support reactions for a rigid body in static equilibrium.

Calculate axial normal stress in a loaded member.

Calculate elastic deformation using stress, strain, and Young's modulus.

Estimate the bending deflection of a simply supported beam.

Calculate a static factor of safety against material yield.

Trace a light ray through reflection from a planar mirror.

Calculate a refracted ray angle using Snell's law.

Calculate a thin lens's focal length from its surface radii and refractive index using the lensmaker's equation.

Calculate image distance and magnification using the thin-lens equation.

Relate aperture diameter, focal length, and f-number.

Relate numerical aperture to the acceptance angle of an optical system.

Calculate field of view from sensor size and focal length.

Trace paraxial rays through a simple two-lens imaging system.

Distinguish the functions of lenses, mirrors, windows, filters, prisms, apertures, and sensors.

Interpret focal length, clear aperture, centration, wedge, and surface-quality entries on an optical component specification.

Explain how refractive index and dispersion affect optical component selection.

Select an antireflection or reflective coating for a specified wavelength band.

Calculate the required clear aperture for a converging or diverging ray bundle.

Select a catalog lens that satisfies a simple imaging requirement.

Identify the mechanical reference surfaces of a catalog optical component.

Establish an optical axis and functional interface datums using SolidWorks reference geometry.

Construct a master layout sketch that controls critical optical positions in an assembly.

Drive optical spacings and interface dimensions using equations and global variables.

Create SolidWorks configurations for alternate catalog optical components.

Import, repair, and simplify supplier STEP models for use in an optomechanical assembly.

Detect component interference and insufficient clearance in a CAD assembly.

Evaluate optical-path and adjustment clearances using section views and component envelopes.

Select a structural material using stiffness, strength, density, stability, and cost criteria.

Compare machining, sheet-metal fabrication, additive manufacturing, and molding for an optomechanical part.

Identify CAD features that create unnecessary machining difficulty or cost.

Select standard screw sizes, thread forms, and engagement lengths for an assembly.

Estimate fastener preload from an applied tightening torque.

Specify a surface finish appropriate to a mechanical interface.

Redesign a bracket for practical CNC machining from common stock.

Create an orthographic part drawing with section and detail views.

Identify the six rigid-body degrees of freedom of an optical component.

Map each contact in a mount to the degree of freedom it constrains.

Detect overconstraint and underconstraint in an optical mount concept.

Design axial retention for a circular lens without blocking its clear aperture.

Select a radial centering method based on accuracy, fragility, and assembly needs.

Apply kinematic mounting principles to a removable optical component.

Design a preload method that maintains contact without overstressing an optic.

Design a tip-tilt adjustment mechanism for a small mirror.

Distinguish size tolerances from geometric tolerances on an engineering drawing.

Construct a functional datum reference frame for an optomechanical part.

Interpret position, flatness, perpendicularity, runout, and profile controls.

Select clearance, transition, or interference fits for mating cylindrical parts.

Calculate a one-dimensional worst-case tolerance stack.

Build a reusable Excel or Google Sheets template that calculates worst-case and root-sum-square results for a one-dimensional tolerance loop.

Convert mechanical variation into optical decenter, tilt, or focus error.

Allocate component tolerances from a system-level alignment budget.

Calculate dimensional change caused by linear thermal expansion.

Calculate differential expansion between an optic and its mount.

Select a compliant mounting feature to accommodate differential expansion.

Construct a first-order passive athermalization calculation for an optical spacing.

Estimate steady one-dimensional heat flow through a structural member.

Estimate gravity-induced optical displacement from structural deflection.

Estimate the first natural frequency of a simple mass-spring representation.

Assess resonance risk by comparing an estimated natural frequency with environmental excitation and recommend a mass or stiffness change.

Identify direct and single-bounce stray-light paths in an optical layout.

Size and position a simple baffle to block an unwanted ray path.

Select surface treatments for light absorption, reflection control, and corrosion resistance.

Identify likely ghost-reflection paths between plane-parallel optical surfaces.

Create a cleanliness and handling plan for exposed optical components.

Write an assembly sequence that protects optics and preserves datum relationships.

Select a basic enclosure strategy for dust, humidity, and splash exposure.

Screen candidate materials for corrosion, outgassing, and cleanliness risks.

Apply functional dimensions and tolerances to a manufactured part drawing.

Create an assembly drawing with item balloons and a bill of materials.

Define measurable requirements for a compact lens-and-sensor imaging assembly.

Create a first-order optical layout for the imaging assembly.

Select catalog optical components that satisfy the first-order layout specifications for the imaging assembly.

Select catalog mechanical hardware and mounting components compatible with the selected optics.

Create a preliminary alignment procedure using mechanical datums and observable focus and centering references.

Conduct a project concept review using requirements, risks, calculations, and design evidence.

Create a top-down parametric CAD layout that controls the critical optical geometry.

Design a deterministic lens-retention and mounting interface for the imaging assembly.

Design a deterministic sensor mount and housing interface for the imaging assembly.

Calculate worst-case and root-sum-square tolerance stackups for critical optical alignment in the imaging assembly.

Calculate thermal expansion shifts and thermal defocus across the operating temperature range of the imaging assembly.

Create a fully dimensioned and toleranced production drawing for the main custom housing component.

Create an assembly drawing with item balloons, assembly notes, and a bill of materials.

Compile a portfolio case study that traces each requirement to design evidence, calculations, risks, and a verification plan.