At Surface Optics, we understand that every application is unique, and an off-the-shelf system may not adequately suit your specific project.
Our electro-optics engineering services cover full product development – from feasibility studies through prototyping and production. Surface Optics has over twenty years of R&D program experience, specializing in custom industrial infrared spectroscopy and imaging spectroscopy systems.
Past custom developments include FTIR reflectometers, VNIR, SWIR, MWIR, LWIR hyperspectral imagers, application-specific multispectral cameras, high dynamic range cameras, focal plane arrays, miniature high-speed cameras, and other advanced imaging systems and spectroscopy instrumentation.
Utilizing our diverse expertise in optical design, fabrication, focal plane arrays, signal processing, and system deployment, we provide comprehensive engineering and manufacturing services. We back our one-stop-shop promise with a talented team of electro-optical, optomechanical, electrical, and software engineers, our established vendor network, and a fully equipped manufacturing facility.
Proof of Concept
In this initial stage, we work with you to clarify application requirements, perform data collection to establish proof-of-concept, and analyze what imaging or spectroscopy technology may be most suitable. We leverage existing Surface Optics technology for data collection of scenes representing application scenarios. Spectral signatures of target materials are identified as well as correlations between spectra and material characteristics. This data will feed into trade studies to determine the best realizable specifications for the proposed system.
Preliminary System Design
Component-level tradeoff studies define the optimum set of technologies to meet the desired prototype. We frame performance parameter tradeoffs against manufacturing factors such as environmental, physical, and cost requirements.
Preliminary system design may include:
- Lens design
- Optics (f/#, focal length, aberration balance, the field of view, spectral/spatial distortions, smile, and keystone)
- Camera (pixel count, spectral quantum efficiency, read noise, frame rate, etc.)
- MLA or filter array
- Prism/grating assembly
- Spectrometer
- Image processing requirements
- The spatial resolution of the instrument
- Spectral bands and spectral range
- Speed of the system in cubes-per-second
- Size and weight of the system
- Power requirements
We conclude the design phase with achievable specifications and theoretical modeling for the final manufactured system’s performance, including NESR, SNR, and MTF of the proposed instrument.
Prototype Engineering
Surface Optics has established significant internal capabilities for high-end electro-optical system development and prototype manufacturing through low and mid-volume production. In-house services include:
Electro-optical engineering
- Full optical assembly design, from the UV through the visible and IR wavelength ranges
- Experience developing broad-band lenses with focal lengths from 50 mm to 264 mm.
- Design of fore-optic, slit window, dispersive element(s)
- Expertise in source types and illumination/detection optics
- Use of industry-leading optical design software, such as Zemax, CODE V, and FRED to optimize the selection of lenses, beam splitter, optical filters, and optical bafflings. They are also used to evaluate system performance in accordance to light scattering and efficiency at the detectors.
- Optical component sourcing
- In-house lens alignment and inspection systems
Electronic system design
Our fully equipped electronics development facility allows for complete hardware-software integration:
- Detector and camera readout circuitry and processing
- Detector and camera communication and control
- Focal plane array integration
- Design and manufacture of analog and digital circuits and complex SMD circuit boards
- FPGA and DSP elements that execute spectral processing algorithms at video rates
- Mult-seat license for VHDL development software
- GUI interfaces
- Incorporation of high-speed computer interfaces such as USB 3.0
Opto-mechanical integration
Our experienced senior mechanical and optical engineers join optical with mechanical designs to produce finished, hardened spectroscopy solutions for our government and commercial customers. We develop our mechanical systems using the latest version of SolidWorks. Our team’s close collaboration achieves precision integration and alignment of the lens, camera, or other optical assemblies, electronics, and housing.
Industrial Automation
Defense, aerospace, and industrial customers often require automation features for stand-alone operation of the finished system. As necessary, we implement motorized/automated shutter and focus control, background normalization, auto compensation for thermal drift, and remote operator interface.
The application of industrial spectroscopy or spectral imaging systems to a particular task requires developing image classification techniques, associated training sets, and mathematical models for classifying target samples. Surface Optics is prepared to deliver these as part of our comprehensive solutions for material identification and anomaly detection, ready for the field or inline deployment.
OEM Manufacturing
Once we complete the optoelectrical and mechanical design to the customer’s satisfaction, we finalize the bill of materials, assembly, alignment, and testing procedures, completing all documentation necessary to transition the product to production.
Our recently expanded 20,000 sq. ft. facility has a dedicated manufacturing floor where various commercial Surface Optics instruments are assembled, tested, calibrated, and serviced. Our technicians are skilled in the fabrication and operation of FTIR instrumentation, optics, mechanical systems, and hyperspectral system technology. Past projects have demanded scaling our manufacturing team for OEM production, and Surface Optics remains prepared to meet volume manufacturing demands.
