Overcoming obstacles to success when transferring to series production – modular system as a key solution, from OPTOMECH.

May 2025. Up to three times shorter assembly times, six times more cost-effective production processes and twelve times lower error rates can be achieved.

Many start-ups are characterized by a high level of innovation and the development of new products and technologies. The implementation of prototypes and small series production is often possible without any problems. However, the step to a series-ready product that can be produced in large quantities and is economically successful is an enormous obstacle. Over 80% of start-ups fail to make the transition from prototype status to series production. OPTOMECH’s modular system is a flexible solution for the optics, optomechanics and precision engineering industry, which enables an optimal production/assembly process, offers fast product adaptations and simplifies any changes. At LASER WoP in Munich, visitors will be able to see for themselves the company’s services and the potential for their own product ideas.

“A working prototype is no guarantee that a product is ready for series production,” says Andreas Hermann, CEO of OPTOMECH GmbH based in Göttingen. The reasons for the difficulties that arise in the implementation process can be manifold, but are often concentrated in inaccurate price and quantity forecasts, but are also caused by inefficient assembly processes or can be found in the design of the product itself. This leads to a misalignment of the production process. For example, injection molded or milled parts must be designed for the subsequent series size. The product itself must also be designed to meet the requirements of series production. In addition, an unsystematic, inadequately thought-out production process means that it has to be constantly readjusted. This results in uncalculated time and rework expenditure and not only leads to a high loss of time, but can also mean considerable additional financial expenditure and unrealizable sales targets.

Customized solutions for the optical industry, medical technology and precision engineering

OPTOMECH GmbH specializes in optical and mechanical technologies and develops customised solutions for industrial applications – especially in optoelectronics and precision measurement technology. The company can draw on more than 30 years of experience and supports its national and international customers in all phases of product development. The main areas of application are in optics, optomechanics and optoelectronics and also extend to medical technology, precision engineering, metrology and laser technology. OPTOMECH also supports customers in the ongoing production of mechanical and optical assemblies and their assembly processes. Special attention is paid to process optimization and design-to-cost strategies, which ensure an efficient and smooth transition from prototype status to series production.

Flexible modular system with modular design enables optimum implementation in series production

One of the most important features of the series compliant design is the modular structure in the sense of a building block system. In optomechanics in particular, it is necessary to divide the optical unit into assemblies. A digital stereo surgical microscope developed by OPTOMECH GmbH serves as an example of this. This highly complex product is characterized by the core functionalities of a focus lens, optical zoom, image filter options and a 2-channel camera unit. These features were already transferred to independent assemblies during the concept phase. This approach makes it possible for each of these modules to be aligned to its own defined reference in a specially developed adjustment tool. In order to function perfectly, this reference must be optically and mechanically precisely aligned with the adjacent module, which means that the optical axis passes through exactly during subsequent assembly and makes further readjustment unnecessary. Ideally, the optical referencing of the individual assemblies should take place where the beams run parallel or an intermediate image is created. In the first case, a collimator can be used for adjustment, as the image is at infinity and the beam direction can therefore be precisely determined. In the second case, a microscope with a fixed working distance enables exact positioning via the focal point. Three-point supports, orientation pins or reference surfaces are used as mechanical reference elements.

Modular design enables production potential to be utilised and leads to a significant reduction in the error rate

The modular design combines several advantages. Firstly, adjusting the individual modules is much easier than adjusting the entire system. As all modules are already pre-adjusted, no further adjustment, or at most minor fine-tuning, is usually required during final assembly. This saves a considerable amount of time and increases the productivity of the manufacturing process and reduces the error rate many times over. A further advantage is that it is now possible to carry out the assembly processes in parallel, which in turn reduces time and makes the manufacturing process more effective. An additional benefit of the modular design is that only individual elements need to be replaced if necessary. OPTOMECH’s experience and design expertise are confirmed in practical application.

In the microscope mentioned above, for example, the optical design was such that the object plane after the objective, the zoom optics and the camera is at infinity. “This made it possible to use each module individually with a telescope and autocollimator. It was particularly important that the reference surface was exactly perpendicular to the optical axis,” says Andreas Hermann. After mounting the modules, no further adjustment was necessary. After the device had proven itself in practical use, the customer asked OPTOMECH GmbH whether variants with other zoom ratios or lens magnifications could also be realised. This was where the advantage of the modular design became apparent, as this was the only way to realise this at short notice.

Visit OPTOMECH GmbH at the LASER World of Photonics 2025 trade fair from 24-27 June in Munich and let us convince you of the technologies and individual solutions for your requirements.

What:                          Laser World of Photonics, Munich 2025

When:                         June 24-27, 2025

Where:                        Germany, Munich Trade Fair Center, Hall B1, Stand 533

Contact person:         Andreas Hermann, CEO Optomech GmbH

Further information can be found at www.optomech.de.