Case Study: Optical Engineering and R&D
Medical Product Development
We fully modelled the prototype system in the Zemax OpticStudio environment. This allowed us to predict the performance in a perfectly aligned scenario, and to then understand the influence of alignment tolerances against a range of parametric variables agreed with the client, using Monte Carlo methods in Zemax. We also assessed the impact of surface reflections within the system and made suggestions as to how the optical design could be further enhanced.
Since we have experimental laboratory capabilities at LumOptica, we were able to make measurements with the first prototype to assess its optical performance against the aforementioned modelling work. We measured image distribution and power levels of LED excitation light at various locations throughout the device.
Following the modelling and measurements tasks, our client was then able to build a second prototype, which we could then similarly test in our labs.
To minimise device cost, we supported the design of two new and bespoke lenses, based on the space constraints and using a material specified by our client. In order to predict their performance we were able to include mechanical distortions which would likely be induced by the lens manufacturing process. This led to a high confidence level in the expected performance of a third prototype system that is now the basis of a CE marked product.
Prototype medical device showing opto-mechanical assembly and ray trace:
Surrogate illumination tool designed and built to aid testing:
Tear down of illumination tool:
Illumination profile before:
Illumination profile after re-design:
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