Active Insight CorporationOptical Alignment Solutions
Active Insight Corporation · Alignment Solutions
When a single lens group can’t absorb all the tolerances, split the optics into two groups and align in two stages — G1 is coarse-aligned onto the CMOS sensor with external vision, then G2 is actively aligned in 6DoF using the module’s own imaging — bringing high-end modules into stable volume production.
This Case · Specifications
Inside the black enclosure and clean chamber is an integrated station combining a 6DoF alignment platform, machine vision, dispensing and UV curing. Scroll down to enter the mechanism.
⟲ Drag to rotate the machine
The top vision camera reads G1’s fiducials for an XYθ coarse alignment from external imaging. Only after G2 is stacked on does active alignment begin — sensor, G1 and G2 now form an imaging optical system, and real image quality (MTF, through-focus curves) feeds back to converge all six degrees of freedom. Loading, coarse alignment, active alignment, dispensing and curing, and final test all complete within a single cycle.
Coarse alignment only guarantees position; image quality cannot be seen until G2 is stacked and the three parts become one optical system. At that point the center and corner peaks each sit at a different Z — field curvature has pulled the focal planes apart. G2 active alignment converges center and corners onto one best focal plane, so every field stands on its peak at the same time — multi-point checkerboard sampling, each field with a paired H/V ROI straddling a vertical and a horizontal edge, while the through-focus curve records the whole convergence.
Both 6DoF alignment stages share one motion platform and machine-vision foundation, and multi-group lens stacks of 7P and above, or two-component groups such as a liquid lens plus a fixed-focus lens, can be aligned on a platform with up to 15 DoF — same lineage as the two-component solution, and the shared core of every AIC equipment solution.
This page uses a multi-group mobile camera module as its example, but two-stage alignment reaches well beyond it.
A 6DoF motion, imaging-feedback and process-integration foundation already extends to camera modules, AR waveguides, light-engine stack alignment and optical coupling. To learn about the case closest to your product, its actual cycle time and accuracy specs, or a customized alignment / metrology solution, get in touch.