Additive Manufactured Optomechanical Assembly for Miniature Imaging
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Solution Overview
Problem
Challenges remain in precisely manufacturing dimensionally compatible optomechanical components and assembling them into functional imaging systems, particularly at smaller dimensions, due to high manufacturing precision and alignment requirements in traditional methods.
Innovation Solution
The use of additive manufacturing (3D printing) enables the digitalized manufacturing of optomechanical components with passive alignment features, reducing part count and simplifying assembly, as demonstrated by the creation of a miniaturized optical microscope with a 3D printed aspherical lens and voice coil motor, allowing for customization and rapid production at a low cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for optomechanical components, then manufacturing precision can be achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple optomechanical components (lens holder, alignment features, mounting structures) into integrated units manufactured via additive manufacturing. This merging reduces the number of separate parts that need to be assembled while maintaining the required dimensional precision through digital modeling and controlled fabrication processes.
Solution Approach 2:
The additive manufacturing process enables single components to perform multiple functions - structural support, optical alignment, mechanical mounting, and positioning - all within one manufactured part. This multi-functionality reduces assembly complexity while maintaining precision through the inherent capabilities of digital manufacturing.
2Reliability
If traditional manufacturing and assembly methods are used, then functional imaging systems can be created, but manufacturing time and costs increase
Solution Approach 1:
The patent incorporates alignment features and positioning structures directly into the additive manufacturing process itself, rather than requiring separate alignment and assembly operations afterward. This preliminary action during fabrication maintains functional performance while significantly reducing total manufacturing time.
Solution Approach 2:
The additively manufactured components include built-in alignment features and self-positioning structures that enable automatic or simplified assembly without requiring complex external alignment tools or procedures. The components essentially assemble themselves with proper positioning, reducing labor time and costs while maintaining functionality.
3Manufacturing precision
If traditional manufacturing methods are used, then optomechanical components can be manufactured, but part count and assembly steps increase
Solution Approach 1:
The patent merges multiple previously separate components into integrated additively manufactured units. For example, lens holders are combined with alignment features and mounting structures into single parts, reducing the total part count while maintaining alignment precision through the integrated design and digital manufacturing process.
Data Source
AI summary
Provided herein are methods of making imaging systems. In one aspect, the method may comprise providing a lens; providing an optomechanical assembly; providing an imaging sensor; and operably connecting the optomechanical assembly with said lens and said imaging sensor, forming said imaging system. In some aspects, providing an optomechanical assembly may comprise manufacturing a component of the optomechanical assembly using additive manufacturing. In some aspects, providing an optomechanical assembly may comprise manufacturing a component of the optomechanical assembly using micro-continuous liquid interface production (μCLIP) 3D printing.