Case Study: Precision Light Control with Micro Prism Components

This case study explores the development and application of micro prism optical components, emphasizing their role in precise light manipulation across various optical systems. Made from materials like glass or plastics, these tiny prisms are vital in devices such as imaging systems, laser technologies, and sensors. The project’s primary goals were to:

Create highly accurate micro prism lenses compatible with a wide range of optical setups.
Enhance manufacturing processes to ensure high quality and cost efficiency.
Partner with customers to provide tailored optical solutions.

Key achievements include the successful production of high-performance lenses, the implementation of sophisticated fabrication and coating processes, and meticulous alignment testing to ensure precision. This project marks a significant step forward in optical technology, offering bespoke solutions for enhanced light control.

Understanding Micro Prisms

Micro prisms are small, transparent optical elements that precisely manipulate light at very small scales. Their finely crafted surfaces allow them to refract or reflect light in specific ways, making them essential in various applications, including imaging devices, laser systems, and optical sensors.

These prisms are designed to control light direction and behavior on a microscopic level, enabling functions like focusing, collimating, and dispersing light. Their compact form factor makes them ideal for integration into miniaturized devices, such as digital cameras, projectors, and medical equipment.

In digital and smartphone cameras, micro prisms improve image quality by correcting optical aberrations and enhancing focusing abilities. They are also crucial in laser systems for tasks like beam shaping and alignment.

Project Overview and Objectives

The project, led by Shanghai Optics and its customer, focused on developing and producing micro prism lenses for diverse optical applications. These lenses enable precise light manipulation, facilitating critical functionalities such as focusing and dispersing light.

The project’s main objectives were:

High Precision and Performance: To develop micro prism lenses that meet stringent performance requirements across various optical systems.
System Compatibility: To ensure these lenses are compatible with a broad spectrum of optical devices, providing versatility and ease of integration.
Manufacturing Optimization: To refine manufacturing processes for maintaining high quality while controlling costs, using advanced micro-nano fabrication and coating techniques.
Customer-Centric Solutions: To work closely with customers, delivering customized optical solutions that meet specific application needs and requirements.

Micro Prism Specifications

Material: Schott N-LASF, Ohara S-LAH
Dimensions: 2.5 x 2.5 x 2.5 mm
Coating: High-reflective coating (Rav 95% mirror, S1) and anti-reflective coating (Rav < 0.8% @ 450-1000 nm)

Manufacturing and Quality Assurance

Anti-Reflective Coatings: To reduce reflection losses (Rav < 0.8% @ 450-1000 nm), multilayer film stack technology was employed. This method involves depositing thin films with varying refractive indices, optimized through optical thin-film design software for precise control over coating thickness.
Assembly and Testing: Automated assembly equipment and precision handling under microscopes were used to ensure accurate alignment and secure assembly of the delicate optical components. Rigorous testing with specialized measurement devices verified that the lenses met all specifications.
Micro-Fabrication Techniques: The creation of micro prisms required advanced micro-nano fabrication methods, including laser cutting and precision CNC machining, to achieve the necessary dimensional accuracy.
High-Reflective Coating Application: We utilized advanced vacuum deposition technologies such as PVD or CVD to apply high-reflectivity coatings, which are essential for achieving the desired optical performance.

The development of micro prism lenses represents a significant achievement in the field of optical technology. Through innovative approaches, customer collaboration, and optimization of manufacturing processes, the project successfully addressed the challenges of creating high-quality micro prism lenses. This advancement not only meets current optical demands but also sets the stage for future innovations in light manipulation technologies.

Contact Shanghai Optics today! We’d be more than happy to discuss your projects and how to best bring them to fruition.