Reverse Engineering Archives

Five OnlineMay 17, 2024Case Study, Reverse Engineering, Reverse Optical EngineeringComments are off for this post

Key Takeaways Reverse Optical Engineering is pivotal for recreating or enhancing optical components, especially when original designs are unavailable or are in need of improvement. This case study showcases the necessary steps in lens reverse engineering, from customer collaboration and sample testing to optical path simulation and final lens assembly. Using advanced tools and iterative optimization, tailored solutions meet precise specifications, ensuring customer satisfaction and industry innovation. The value of reverse engineering extends to revitalizing legacy products and staying abreast of evolving optical industry demands, highlighting its crucial role in technological advancement and customer-centric design. Case Study: Lens Reverse Engineering Introduction Reverse optical engineering, including lens reverse engineering, entails comprehending the functionality of existing optical components or systems through examination. This facilitates the replication or enhancement of these components. It proves advantageous when the original design is inaccessible or when there’s a desire to enhance existing technology. This method is invaluable for crafting customized optical systems for specific needs, discerning original engineering endeavors, or replicating intricate designs efficiently and cost-effectively. This approach empowers individuals to refine the focal point of an optical system and capture detailed object information for subsequent analysis and manufacturing using the refined design. The traditional design workflow is typically “from scratch”. In reverse engineering, you start with an off-the-shelf machine or component and work backwards to disassemble each component or layer. Due to various reasons, the original manufacturer of this lens has stopped production, but there is still a small amount of demand in the market to continue the production of the lens in reverse. Specification Diameter 32mm Focal length 25mm（magnification 10X） Eye relief 25-250mm Lens reverse engineering process Customer needs to provide a sample lens First of all, the customer needs to provide two sample lenses, one for lens image quality testing, and the other for destructive testing of the parameters of the lens and structural components. At the same time, it is also necessary for the customer to provide the use scenario of the lens, so as to pay attention to the customer’s application in the later design. Figure 1 is a customer sample lens. Figure 1. Customer’s sample lens Design optical path simulation The customer needed an eyepiece with a lens that could achieve a balance between 25-200mm eye relief distance and imaging using a smartphone, and the customer had to be able to look away from the optics and maintain a good image. Key parameters are as follows: Figure 2. Customer Sample Diagram Figure 3. Optical Schematic Diagram Figure 2 and Figure 3 simulate the visual usage of two different lens Settings in existing products. Figure 2 lens does not work for long visual distance, but works well for short visual distance and has high lens resolution. Figure 3 applies to short and long visual distances, but with reduced edge resolution, the distortion is greater when using a smartphone. Retinal image Test the overall parameters of the lens Initially, the primary parameters of the lens undergo testing, encompassing focal length, entrance pupil diameter, back intercept, and image quality. Simultaneously, the lens dimensions are examined, with no alterations made to them during subsequent reverse engineering processes. Disassemble a lens and input the test lens data into the optical design software, such as Zemax. It is necessary to input the test data into the optical design software. If there is any error, the parameters need to be optimized. Spec Radius Thickness Material Diameter Doublet 50.308 10.488 H-ZK6 32 -22.723 1.477 H-ZF52A 32 -55.444 0.26 32 Singlet 33.006 6.148 H-LAK7A 32 Infinity 32 MTF (modulation transfer function) Test Result Lens overall test results Shorten the lens focal length to 25mm according to customer requirements, and optimize the lens image quality to meet customer requirements. The test results of the newly processed lens are as follows. Assembly and take pictures The actual shot picture is as follows. Lens structure Lens Reverse Engineering Conclusion The process of lens reverse engineering outlined in this case study demonstrates the meticulous steps involved in recreating optical components to meet specific requirements. By combining customer samples, rigorous testing, and advanced design software, we can craft unique solutions even without the original blueprint. Throughout the journey, collaboration with the customer remains paramount. Their input and feedback guide the design process, ensuring that the final product aligns with their needs and expectations. Additionally, iterative testing and optimization guarantee that the lens meets the desired specifications, such as focal length, image quality, and eye relief distance. Ultimately, this case study exemplifies the value of reverse engineering in revitalizing discontinued products or enhancing existing technology. By leveraging reverse engineering techniques, manufacturers can breathe new life into legacy products and consistently address evolving customer demands in the optical industry. Please contact us if you’d like to request a quote on your next project. Related Content

Reverse Optical Engineering Case Studies from Avantier

Johnny LeeJanuary 12, 2023Aerospace and Defense, Case Study, Consumer, Industrial, Life Science, Medical, Reverse Engineering, Reverse Optical EngineeringComments are off for this post

At Avantier, we are our proud of our track history in assisting customers to solve problems using reverse optical engineering. Here are three case studies. Case Study 1: Reverse Engineering an OFS 20x APO Objective Lens for Bioresearch Genetic engineering requires using precision optics to view and edit the genomes of plants or animals. One world renowned bio research lab has pioneered a new method to speed plant domestication by means of genome editing. While ordinary plant domestication typically requires decades of hard work to produce bigger and better fruit, their methods speed up the process through careful editing of the plants’ genome. To accomplish this editing, the bio research lab used a high end OFS 20x Mitutoyo APO SL infinity corrected objective lens. The objective lens performed as desired, but there was just one problem. The high energy continuous wave (CW) laser waves involved in the project would damage the sensitive optical lens, causing the objective lens to fail. This became a recurrent problem, and the lab found itself constantly replacing the very expensive objective. It wasn’t long before the cost became untenable. We were approached with the details of this problem and asked if we could design a microscope objective lens with the same long working distance and high numerical aperture performance of the OFS 20x Mitutoyo but with better resistance to laser damage. The problem was a complex one, but after years of intensive study and focused effort we succeeded in reverse engineering the objective lens and improving the design with a protective coating. The new objective lens was produced and integrated into the bio research lab’s system. More than three years later, it continues to be used in close proximity to laser beams without any hint of failure or compromised imaging. Case Study 2: Reverse Engineering an OTS 10x Objective Lens for Biomedical Research Fluoresce microscopy is used by a biomedical research company to study embryo cells in a hot, humid incubator. This company used an OTS Olympic microscope objective lens to view the incubator environment up close and determine the presence, health, and signals of labeled cells, but the objective was failing over time. Constant exposure to temperatures above 37 C and humidity of 70% was causing fungal spores to grow in the research environment and on the microscope objective. These fungal spores, after settling on the cover glass, developed into living organisms that digested the oils and lens coatings. Hydrofluoric acid, produced by the fungi as a waste product, slowly destroyed the lens coating and etched the glass. The Olympus OTS 10x lens cost several thousand dollars, and this research company soon realized that regular replacement due to fungal growth would cost them far more than they were willing to pay. They approached us to ask if we would reverse engineer an objective that performed in a manner equivalent to the objective they were using, but with a resistance to fungal growth that the original objective did not have. Our optical and coating engineers worked hard on this problem, and succeeded in producing an equivalent microscope objective with a special protective coating. This microscope lens can be used in humid, warm environments for a long period of time without the damage the Olympus objective sustained. Case Study 3: Reverse Engineering a High Precision Projection Lens A producer of consumer electronics was designing a home planetarium projector, and found themselves in need of a high precision projection lens that could project an enhanced image. Nothing on the market seemed to suit, and they approached us to ask if we would reverse engineer a high quality lens that exactly fit their needs but is now obsolete. We were able to study the lens and create our own design for a projector lens with outstanding performance. Not only did this lens exceed our customer’s expectations, it was also affordable to produce and suitable for high volume production.