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Precision Optics

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Need a precision optics supplier for an existing product?

Fluidigm

Problem:
Our Client, a leading manufacture in the bio tech industry, was dissatisfied with one of their subcontracted vendors. Yield levels were low for the contracted part which affected both pricing and delivery. Running a real-time production line, the client needed to find a vendor who had extensive engineering capabilities, could respond quickly and maintain quality.

Solution:
In order to land this contract, the vendor needed to have seamless collaboration with the client. They needed to establish an internal process and seamlessly integrate into a running production line.

The evaluation was based on the ability to deliver several services: material procurement, complex engineering, multi-step fabrication, evaporative coating, testing and shipping to a third party vendor arriving in time for real-time assembly. This project highlighted the challenges of changing vendors in a real-time production line.

ios™Optics Difference: Existing Product: Precision-First Product and Mass Production
            • Fabrication with an external team.
            • Complex fabrication and coating within a pre-established timeline.
            • High yield levels and drove costs down.
            • Tight production processes guaranteed delivery times.
            • All items were fabricated and coated in-house.
Although the quality of the optics produced was important, the ability to deliver all elements in the allotted time frame for integration in a running manufacturing line was the determining factor in ios™ Optics landing this contract.

Company Product: Bio Tech Tools

Industry Served: Life Sciences

Product Integration: Input/Output rods used in gene analysis

Manufacturing Challenge: Existing Product: Precision and delivery issues

Stage(s):
R&D Prototype Engineering

Project Timeline: 8 weeks

Project Date: September 2003

Need a supplier with extensive experience engineering prototypes?

Continuum

Problem:
Our client, a global leader in custom manufactured lasers used for scientific and industrial applications, developed a new precision laser system. Once design work was complete, engineers needed to partner with a company that could provide custom manufactured optics-both to be included in the laser and to be provided as lens kits for beam modification.

Solution:
The R & D team was seeking a partner with high standards, a strong portfolio of prototype design, a deep understanding of fabrication and experience with a wide product range The supplier had to be able to engineer a 11 prototypes, test them and then be able to move to first production with all of the parts.

With research grade standards required [10-5 LQ], the ideal vendor would produce and coat the lenses and lens kits in-house. All ten items designed needed to move through R&D and prototype testing before being integrated into the laser system.

ios™Optics Difference: New Product—R&D, Prototype Engineering, Design & Testing and First Product
• Dedicated engineering team.
• Large inventory of custom tools.
• Multiple production runs.
• 10-5 Laser Quality [LQ].
• All items were fabricated and coated in-house.

Today ios™ Optics is the primary custom optics provider. Having passed all initial phases, the lenses are in the final stages of testing for integration into the laser system. When approved the client will move to mass production.

Company Product: Custom Laser Manufacture

Industry Served: Scientific & Industrial

Product Integration: Lenses & lens kits for lasers

Manufacturing Challenge: New Product: R&D, Prototype Engineering, Design & Testing and First Product

Stage(s):
R & D
Prototype Engineering Design & Testing
First Product

Project Timeline: 12 weeks

Project Date: February 2011

Need an engineering team with experience moving from first product to mass production?

KLA-Tencor

Problem:
Our client, the world’s leading supplier of inspection and yield management equipment, pioneered a new precision inspection system. With R&D complete and test runs showing good results, they began shopping for a fabrication house to produce both individual components and optical kits.

Solution:
To secure the project, the vendor needed to demonstrate the ability to fabricate and coat the light pipes with extremely tight tolerances and to supply not only individual components but to manufacture multi-component optical kits.

Client specifications on the octagonal homogenizers included a zero tolerance for chips on the faces and a near-zero tolerance on the remaining eight sharp edges.

Not only were components needed for integration into product, but each product required a custom ordered optical kit containing up to nine different components.

ios™Optics Difference: New Product—Design & Testing, First Product and Mass Production
            • Collaboration with engineering and R&D teams.
            • Tight coordination of mass production reducing costs.
            • Fabrication guaranteed near-zero tolerance.
            • All items were fabricated and coated in-house
Seeking a custom optics manufacturer, the client sought a vendor who was able to coordinate dozens of parts and ramp- up quickly leveraging a large, local manufacturing floor.

Encountering quality issues with current supplier?

Hach Ultra

Problem:
Our client, a leading developer and manufacturer of particulate counters, had chosen to use stock lenses in their product. They then subcontracted with an external vendor to have the lenses diced and coated in a multi-step process. Encountering very high QA rejection levels with their current vendor, the client was looking for a supplier with deep engineering experience to improve yield levels.

Solution:
As a single source supplier in fabrication and coating, ios™Optics needed to demonstrate superior quality in fabrication and to increase yield levels.

The specific part being manufactured was challenging due to the shape of the lens. Cylindrical lenses present challenges as they require both a detailed understanding of the substrate material as well as a core understanding of the processes required in fabrication. Because of profitability loss with the previous supplier, the vendor was looking for an engineering team who could shorten fabrication times and make up the loss encountered.

ios™Optics Difference: Existing Product—Quality: Mass Production
            • Complex fabrication and multi-step coating.
            • High yield levels and shorter fabrication times driving down costs.
            • Tight production process guaranteed delivery times for integration into existing product line.
            • All items were fabricated and coated in-house.

When landing this contract well over a decade ago, ios™Optics demonstrated the ability to produce a quality lens and meet all of the vendor’s requirements. Through the years economic downturns have required ios™Optics to keep a tight hold of both quality and profitability issues. Today in its 15th year, this contract demonstrates an ongoing commitment to work with clients and be the vendor of choice.

Company Product: Precision inspection & Yield Management Equipment Manufacture

Industry Served: Semiconductor

Product Integration: Apodizer used in Back-End Defect Inspection Equipment

Manufacturing Challenge: New Product: Design & testing, First Product and Mass Production

Stage(s):
Mass Production Design & Testing
First Product

Project Timeline: 8 weeks

Project Date: March 2008

Testimonials

"Our company, Bachur & Associates has been a customer of IOS for over 20 years. They have been, and still are, the major supplier of optical components to our company. We have found that IOS is capable of producing quality parts, both standard and custom, at a reasonable cost, and in a timely manner. Their excellent personal service, coupled with high quality parts, has allowed us to meet our many needs. We expect this long-standing relationship to continue for a long time, as it has proven to be good for both companies".
Jerry Bachur, CEO
Bachur & Associates

"I have found ios^™ Optics' s quality to be superlative. Their pricing is fair and reasonable, with delivery in a very timely manner."
Barry Clerkson, Principal Engineer
Fluidigm