Active Alignment | Jabil Kasalis

Active Alignment

Our Pixid systems have been used to actively align and assemble some of the smallest, most precisely assembled cameras in the world. Assembly of high precision camera and projector modules is both a science and an art, and by applying our most sophisticated algorithms while simultaneously implementing creative approaches to design and function, Jabil Kasalis has developed a system that embodies the best of both worlds.

Pixid systems position lenses in six axes in three-dimensional space to achieve optimal alignment, relative to the image sensor, to obtain the highest optical performance. By using active alignment, the resulting optical modules have the most uniform clarity available in today's market of extremely compact cameras and projectors.

Our systems rely on the following technologies, which collectively address the challenges in active alignment and assembly of opto-electronics:


ADAPTIVE INTELLIGENCE

Adaptive Intelligence is an advanced software suite that uses statistical process control, embedded in our manufacturing systems, to streamline the active alignment, assembly, and testing processes. The unique algorithm in our software uses historic feedback to constantly improve performance.


ADHESIVE DISPENSE

Pixid systems utilize a vision-guided dispense substation for accurate and repeatable dispensing of adhesive. The lens is aligned with adhesive already on its periphery. Once the final lens position is determined, the adhesive is solidified, or cured, by using UV light to initiate a polymer reaction. Adhesive type is carefully determined based on technology requirements.


UV CURE

Our automated UV (ultra violet) module performs the crucial task of hardening the adhesive that is between the two optical components and provides several advantages, including long life and consistent UV power, lower lifetime costs, and lower temperature at adhesive site.


ADVANCED TESTING

Our optical test suite is the most comprehensive in the industry and custom tests can be created. Whether you use the tests for in-process testing and characterization or post-process final testing and validation, the tests are state-of-the-art and consistent, with a cycle time matched to your production.


DYNAMIC SHRINKAGE ADJUSTMENT

This technology accurately measures the glue gap in each unit, and dynamically compensates for glue shrinkage during the alignment process, allowing for even greater precision in the final product. This is an optional technology.


ADVANCED QUALITY CONTROL

The advanced quality control measures available include verification of volume and position of adhesive, temperature monitoring, target intensity measurements, fixture tracking using bar code verification, part serial number tracking, UV light measurements, and bond gap measurements. These are all optional technologies.


CUSTOMIZATIONS

Every customer has a set of product requirements and we work closely with them to customize each system they purchase to meet those requirements, whether it’s a specific type of target we need to design or a special adjustment to the software.


PRECISION MECHANICS

Jabil Kasalis provides expertise in the design of high precision tooling, allowing for repeatable mechanical referencing for the device under manufacture while also allowing an electrical connection for powering the device and enabling high speed data transfer.


SPECIALIZED ALGORITHMS

Our software team develops advanced algorithms for analyzing the active alignment process. These algorithms are created specifically for each system to optimize the speed and accuracy of alignment while prioritizing product parameters and requirements.