Reverse Optical Engineering

Many engineers utilize standard or off-the-shelf lenses when building new-product prototypes. However, relying on a unique lens component from a specific supplier can lead to high costs and potential disruptions in your production development plan. If the supplier discontinues the lens or fails to meet your application requirements, your project can be significantly impacted. In these situations, analyzing and recreating the lens component—a process known as reverse engineering—could be a cost-effective way to get your project back on track.

What Is Reverse Optical Engineering?

Optical reverse engineering is a process that optical engineers utilize to understand and redesign existing optical lenses or assemblies. This process involves starting with a finished product and working backward, deconstructing the optical system to analyze how its components contribute to – or fall short of – achieving the intended optical performance. After a thorough examination of the system, engineers can either replicate it precisely or refine the design to better meet a client’s specific needs.

You may decide to use an optical reverse engineering program if:

• You need to replace an off-the-shelf product due to its price or availability
• You don’t have access to the full specifications of a lens you rely on
• You want to improve an off-the-shelf lens to fulfill challenging requirements

Optical reverse engineering employs a variety of techniques and tactics to gain a comprehensive understanding of the optical system. At Shanghai Optics, our reverse engineering process involves an in-depth study of the optical lenses and lens assembly. Our reverse engineering program follows these key steps to ensure reliable and useful outcomes:

1. Sample testing: Our optical engineers start by testing the sample as an entire system, which gives us an idea of how effectively the system performs its intended tasks.
2. Disassembly and mapping: Next, we disassemble the system and study its construction. In this stage, we separate the optics from mechanical components, mapping their arrangement and attributes.
3. Optical characteristic measurement: After mapping the assembly, we conduct additional tests on the optics. Using a range of cutting-edge metrology equipment and analyses, we determine the dimension, radius, surface accuracy, air space, centering, coating and refractive index of every lens.
4. Redesign: Once we understand the optic system’s construction, we can begin redesign. The techniques used in this step will differ depending on your goals for the study.

After reverse engineering the optical component and refining the design, we will manufacture the new system. Using Modulation Transfer Function (MTF) and other measurements, we will demonstrate how the redesigned system either matches or surpasses the performance of the original.

When in doubt, feel free to consult our expert opinion here.

A reverse engineering program helps businesses understand, replicate and improve the optical systems they rely on. Specific benefits of reverse engineering for optics include:

• Uninterrupted production: Reverse engineering an optical component gives you more control over your supply, eliminating the chance of manufacturing interruptions that can occur when a supplier discontinues or modifies an important product.
• Optimized performance: With a greater understanding of your optical components, you have the ability to make improvements. If you’re looking to develop a solution to a unique optics problem, reverse engineering can aid in the process.
• Reduced costs: Reverse engineering and redesign can provide a lower-cost alternative to expensive off-the-shelf products from exclusive vendors.
• Ownership of the design: Customers get a chance to own their unique design when S.O. complete the design and successfully build the prototype.

While optical reverse engineering offers numerous advantages, it’s not always the ideal solution. In some cases, it may be easier to design a custom lens from scratch. If you’re unsure whether reverse engineering is the right approach for your project, our reverse engineering consulting services can help you assess your needs and determine the optimal path forward.

You can find more case studies on optical reverse engineering here.

Get Optical Reverse Engineering Services From S.O.

Reverse Optical Engineering involves analyzing and recreating existing optical components, especially when the original designs are unavailable. This process allows engineers to understand the lens’s use through disassembly, enabling them to meet customer-specific needs. Focusing on the system’s focal point and enhancing it enables it to produce high quality lenses. Additionally, it facilitates the creation of a custom optic system, integrating analysis and manufacturing for improved performance. This method is valuable for refining traditional design workflows and adapting existing optical systems for modern applications.

At Shanghai Optics, we have more than 60 years of experience reverse engineering, designing and manufacturing high-quality optical lenses. We’ve used reverse engineering to help many businesses find innovative solutions to unique optics challenges. Contact an S.O. representative today to learn more.

Our Expertise can Solve Your Optical Engineering Problems:

• Optical design and analysis
• Optical fabrication
• Optical assembly and optical system alignment
• Optical coating design, analysis, and fabrication
• Opto-mechanical design and analysis
• Optical system test equipment design and analysis
• High precision optical alignment and optical assembly
• A passion and persistence for high precision measurement and analysis