Maximizing production yield and performance in optical instruments through effective design and tolerancing

The focus of this paper is concerned with the practical aspects of designing optical instruments which are intended for production in large or even small quantities . Certain aspects of performance are required of an instrument which is its reason to exist . It is usually expedient, plus fiscally and ecologically sound, to strive for an overall efficient use of resources in the life cycle of the instrument (i .e ., keep the net cost down) . This includes the processes from concept through design, prototypes, production, use, and disposal . The design and tolerancing aspects of the process have a major effect on the life cycle cost and efficiency of the system and that is the principal subject of this paper . We discuss what makes up the cost of a lens and the effects of tolerances and other factors on that cost . This results in a new lens cost estimation formula. We describe the interactions of lenses and lens cells from the tolerance viewpoint . We then explain the principles whereby the system tolerances can be determined which will give the minimum cost system which meets the performance requirements . We conclude with an example from real life of the preliminary application of the principles .