Precision Alignment Uniform Laser Line

Introduction

A world leader in machine vision turned to Diode Laser Concepts for an OEM “next gen” laser line source with demanding optical specifications and opto-mechanical alignment requirements. DLC’s novel laser solution and optical metrologies provided predictable and highly accurate alignment of the uniform laser line to the 3D imaging plane, creating a true plug-play laser system in the customer product and no additional alignment in the field.

The Challenge

• Fan angle and intensity uniformity of laser line requiring custom Powell lens, and alignment metrologies.
• Precise optical alignment of uniform line relative to mechanical reference plane.
• Demanding line thickness requirements through multiple field ranges.
• Zero optical anomalies within the laser line.
• High volume requiring custom manufacturing optical alignment system, station, and processing GUI.

Our Solution

• 658nm, 3.2±0.2mW, TTL control.
• Custom Powell lens producing >90% intensity uniformity.
• Optical plane alignment ±20µm, pitch <0.03°.
• Tightly tolerance mechanical package with precision locator pins.
• Novel laser diode align and attachment technology.
• 5 degrees of freedom Powell lens micro alignment.
• High resolution/speckle free line quality metrology capable of detecting the faintest optical anomalies.

Implementation & Manufacturing

• Collaboration with the customer including site visits, weekly video meetings, mechanical, electrical, and optical design, iterative prototyping, and metrology.
• Custom manufacturing alignment station with real-time line quality inspection for high volume throughput.
• Rigorous environmental testing.
• Met all HALT and environmental testing for customer application.

Why Diode Laser Concepts

• A leading innovator in diode-laser-based photonics, offering tailored solutions from custom laser modules to fully engineered advanced systems.
• Top-tier engineering team with proficiency in physics, optics, mechanics, electronics, and thermal design.
• Uses Design-for-Manufacturing (DFM) decision making throughout a project.
• Advanced manufacturing facilities, processes, and capabilities using custom designed opto-mechanics and metrologies for precision optical alignment and system-level integration.
• Highly collaborative development process ensuring your project success.
• On-time and on-budget in meeting your most demanding specifications.
• Commitment to long-term and world-class customer service.