Function-to-drawing translation
Allocate only the tolerances and controls required for system performance and assembly.
Custom optical fabricationPalo Alto, California
COMPONENTS / COATINGS / ASSEMBLIES
Fabrication strategy begins with function, tolerance, and verification.
PAO converts optical performance into buildable component and assembly specifications, then manages qualified fabrication, coating, metrology, acceptance, and engineering change through delivery.
SYSTEM WORKFLOWPAO / 01
01Function
02Specification
03Process
04Metrology
05Accepted hardware
Custom lenses, prisms, mirrors, windows, filters, coatings, and optical assemblies.
01Engineering reality
The right fabrication process is part of the optical design.
Material, geometry, tolerances, coatings, datums, cosmetic limits, metrology access, quantity, schedule, and cost interact. Over-specification adds cost; under-specification transfers risk into assembly and test.
Process-aware design
Match geometry, material, surface, coating, centering, and edge definition to a viable production route.
Objective acceptance
Define metrology, sampling, data format, cosmetic criteria, and nonconformance handling before fabrication.
02Engineering scope
Engineering control from specification through accepted hardware.
PAO remains the technical interface across design, fabrication review, metrology, assembly, and issue resolution.
Define a technical work packageOptical specification
Material, geometry, surface form, irregularity, roughness, centration, wedge, edges, clear aperture, and cosmetics.
Fabrication route
Grinding, polishing, molding, diamond turning, freeform processing, replication, dicing, or application-specific methods.
Coating definition
Spectral, angular, polarization, durability, witness sample, environmental, cosmetic, and handling requirements.
Mechanical interfaces
Datums, bevels, flats, clocking, bonding surfaces, mounting loads, retention, and assembly access.
Metrology and acceptance
Test method, setup, datum strategy, uncertainty, sampling, reports, first-article review, and lot criteria.
Supplier and change control
Technical review, questions, deviations, nonconformance disposition, corrective action, and revision control.
03Technical envelope
A broad component set with system-level engineering control.
Representative capability is shown with the context needed to qualify it. Program requirements control the final architecture and acceptance values.
Lenses and lens groups
Spherical, aspheric, cylindrical, achromatic, relay, objective, condenser, and custom imaging elements.
Prisms, windows, and filters
Beam-turning, splitting, spectral, protective, wedged, bonded, and application-specific components.
Mirrors and freeforms
Flat, spherical, aspheric, off-axis, elliptical, and freeform reflective optics.
Coated and aligned assemblies
Optics, spacers, cells, bonding, centering, alignment, test, and controlled subassembly delivery.
REFERENCE ENVELOPE
GeometryFlat to freeformIncluding spherical, aspheric, cylindrical, off-axis, and diffractive features
MaterialsGlass / crystal / polymer / metalSelected for spectrum, environment, process, and cost
Spectral rangeUV to infraredMaterial and coating process dependent
Delivery levelElement to aligned assemblyWith project-specific metrology and acceptance data
Capability depends on geometry, size, material, tolerance, coating, metrology, quantity, and schedule as a complete set. PAO confirms the production and verification route before commitment.
04What you receive
Engineering outputs your team can review, build, test, and maintain.
The exact package follows the program stage and scope. Assumptions, interfaces, decisions, and acceptance evidence remain visible.
Controlled optical drawing
Unambiguous dimensions, datums, tolerances, surface, coating, cosmetic, edge, and marking requirements.
Fabrication and inspection plan
Process assumptions, hold points, tooling, metrology, witness samples, sampling, and acceptance.
Supplier technical package
Models, drawings, specifications, reference files, revision status, and question-resolution record.
First-article review
Data review, exceptions, fit and function checks, root cause, and corrective-action decisions.
Lot acceptance record
Certificate and report review, traceability expectations, approved deviations, and release status.
Assembly support
Mounting, cleaning, handling, bonding, alignment, verification, and issue-resolution guidance.
05Controlled delivery
A local engineering interface from first review through release.
PAO leads the technical work, coordinates specialized fabrication and production resources under the project quality process, and keeps responsibility for requirements, interfaces, evidence, and issue closure clear.
- 01
Technical intake
Define the system boundary, decision to be made, current evidence, constraints, and confidentiality path.
- 02
Requirements and risk
Create measurable requirements, interface assumptions, performance budgets, and a ranked technical risk register.
- 03
Architecture and proof
Compare viable concepts and retire the highest-risk assumptions with analysis, breadboards, or targeted tests.
- 04
Detailed engineering
Develop controlled optical, mechanical, calibration, test, and supplier-ready documentation.
- 05
Build and verification
Support procurement, assembly, alignment, test correlation, root cause, and evidence-based iteration.
- 06
Release and transfer
Close acceptance criteria, configuration, supplier questions, manufacturing issues, and production handoff.
06Qualification questions
Questions engineering teams ask before engaging.
01Can PAO fabricate from an existing drawing?
Yes, after a manufacturability and acceptance review. PAO identifies ambiguous, conflicting, unnecessarily costly, or unmeasurable requirements before placing the work into production.
02Do you provide inspection data?
Inspection and data requirements are defined per project. Options can include material records, dimensional results, interferometry, surface data, coating scans, cosmetic inspection, and assembly-level performance.
03Can you support low-volume prototypes and later production?
Yes. The prototype route is selected with the future production method in mind, while recognizing that tooling, process capability, inspection, and economics may change with volume.
08Start a conversation
Send the function, drawing, model, or failed quote.
PAO can start from a performance requirement, review an existing specification, or recover a component that is difficult to fabricate or verify.