The challenge: A semiconductor capital equipment manufacturer was integrating a next-generation brightfield objective lens array. Active alignment is slow and expensive at integration time — they needed tooling precise enough that the optics would land in spec passively, with no adjustment.

What we designed: Passive alignment tooling driven entirely by Geometric Dimensioning & Tolerancing. Every datum, tolerance, and stack-up was engineered so that when parts met spec, alignment happened by construction. The design included FEA stress analysis on the flexures that provide controlled compliance without sacrificing repeatability.

The result: The tooling let system engineers integrate the next-generation objective lens seamlessly — ahead of schedule.

We also improved prototype optical alignment tooling by applying manufacturing process knowledge and GD&T, and managed the Collection Optics System solid model assembly.

The skills involved: GD&T, tolerance stack analysis, flexure design, FEA, passive optical alignment, design for assembly, semiconductor equipment.

Fighting an alignment or tolerance problem? Contact us and bring your stack-up — we’ll take a look.