Unknowns hidden inside the architecture
Identify the few optical, mechanical, thermal, calibration, or supplier assumptions that the prototype must resolve.
Optical prototype developmentPalo Alto, California
DESIGN / SOURCE / BUILD / VERIFY
Optical design transfer to manufacturing: prototypes built to answer the product's hardest engineering questions.
Palo Alto Optics develops optical prototypes for teams that need measured hardware evidence, not only design files. PAO can enter from requirements, an existing Zemax or CODE V model, CAD, bench hardware, or a failing prototype, then deliver controlled designs, sourced components, integrated hardware, alignment and calibration records, verification results, and a manufacturing-ready next-build package.
SYSTEM WORKFLOWPAO / 01
01Risk
02Design
03Custom parts
04Integrated build
05Measured evidence
A single engineering thread from optical model to measured hardware.
01Engineering reality
A useful prototype is an experiment with a controlled configuration.
Fast hardware has value only when the team knows what was built, what was measured, which assumptions were tested, and what must change before the next stage.
Design and sourcing disconnected
Select materials, tolerances, coatings, mounts, and vendors as one build strategy rather than after the model is complete.
Bench success without transfer evidence
Capture configuration, alignment, calibration, test conditions, deviations, and acceptance data so the result can be repeated.
02Project fit
Contact PAO when the next hardware build must answer a defined engineering or business decision.
The best fit is a team with a concept, model, partial design, bench setup, or failing prototype that needs coordinated optical design, sourcing, assembly, calibration, test, and a credible next-build package.
Feasibility needs physical evidence
A focused breadboard or optical engine must prove signal, resolution, field, illumination, alignment, or a critical interface before larger investment.
Existing hardware is underperforming
You need measured configuration, model correlation, root-cause isolation, and a targeted redesign instead of another uncontrolled build.
The program is approaching transfer
Prototype decisions, supplier inputs, assembly steps, calibration, acceptance methods, and open risks need to be captured for repeatable builds.
ENGINEERING DECISION TABLE
Inputs that change the architecture, acceptance method, and program risk.
| Input condition | Key metric | Design choice | Risk if unresolved |
|---|---|---|---|
| Decision the prototype must support | Pass/fail requirement and evidence confidence | Breadboard, integrated engine, or product-intent build | The build consumes time without resolving the program decision. |
| Fidelity and reusable interfaces | Optical, mechanical, electrical, and software representativeness | Temporary fixtures versus controlled product interfaces | Bench success cannot transfer to the product. |
| Custom parts and supplier capability | Tolerance, lead time, metrology, expected yield | Catalog, modified catalog, prototype process, or production process | Late parts, unverified deviations, or a non-scalable design. |
| Acceptance and next-build intent | Measured result, uncertainty, repeatability, open risk | Test fixtures, sampling, configuration record, release gate | The team cannot reproduce or act on the result. |
SELECTED ENGINEERING EVIDENCE
Published scope, verification method, and disclosure boundary.
These records describe documented engineering experience or the evidence plan PAO uses for new work. They do not imply that prior-employer programs were PAO customer engagements.
Custom optical hardware delivery experience
- Scope
- Documented prior-role work spanning optical design, tolerance analysis, supplier communication, optomechanical interfaces, metrology, and system test.
- Verification
- Controlled prescriptions and drawings, part data, alignment records, image or optical tests, and comparison against modeled behavior.
- Boundary
- Past customer identities, precise specifications, quantities, and confidential results are intentionally withheld.
PAO prototype evidence package
- Scope
- Development plan, released configuration, sourcing record, as-built and alignment record, verification report, and next-build actions.
- Verification
- Methods, equipment, test conditions, uncertainty inputs, measured results, deviations, and open issues are retained together.
- Boundary
- Hardware ownership, supplier responsibility, acceptance limits, and publication rights are defined in the project scope and NDA.
03Engineering scope
Engineering ownership through the complete prototype loop.
The prototype can be a focused breadboard, an integrated optical engine, or a product-intent subsystem depending on the decision the team needs to make.
Define a technical work packagePrototype definition
Decision to be made, requirements under test, interfaces, fidelity level, schedule, budget drivers, and success criteria.
Optical and mechanical design
Architecture, detailed models, tolerances, optomechanics, drawings, assembly strategy, and verification planning.
Custom component sourcing
Supplier-ready optics and mechanical packages, quote review, technical questions, fabrication oversight, and incoming data review.
Assembly and alignment
Fixtures, datums, adjustment strategy, build sequence, alignment measurements, cleaning, handling, and configuration control.
Calibration and test
Reference artifacts, procedures, data capture, model-to-test comparison, failure isolation, and measured acceptance results.
Iteration and transfer
Issue closure, design updates, build record, next-unit recommendations, supplier controls, and product-development handoff.
04Technical envelope
Prototype formats matched to the program decision.
Representative capability is shown with the context needed to qualify it. Program requirements control the final architecture and acceptance values.
Architecture demonstrator
A focused setup to validate optical feasibility, signal, field, image quality, illumination, or a critical interface.
Integrated optical engine
Custom optics and optomechanics assembled with source, sensor, display, scanner, or stage interfaces.
Prototype recovery
Measurement, model correlation, root-cause isolation, redesign, and targeted rebuild for hardware missing requirements.
Pre-production build
Product-intent documentation, controlled suppliers, assembly and test instructions, acceptance data, and transfer support.
REFERENCE ENVELOPE
Starting pointRequirement to existing hardwareNew architecture, detailed design, redesign, or diagnostic recovery
Prototype fidelityBreadboard to product-intent subsystemChosen from the decision, risk, schedule, and transfer objective
DeliveryData package and hardwareExact deliverables and ownership defined in the project scope
AcceptanceRequirement-linked evidenceTest conditions, configuration, method, uncertainty, and result recorded
Prototype scope, hardware ownership, supplier responsibilities, test methods, schedule, and acceptance criteria are defined before commitment. Performance is verified against the agreed configuration and conditions.
05What 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.
Prototype development plan
Objectives, requirements under test, fidelity, interfaces, risk retirements, schedule, responsibilities, and decision gates.
Design release package
Optical models, drawings, CAD, tolerances, BOM, specifications, assembly strategy, and controlled revisions.
Sourcing record
Supplier selections, technical clarifications, approved deviations, inspection data, status, and receiving decisions.
Build and alignment record
As-built configuration, serial or lot references, fixtures, alignment results, calibration state, and deviations.
Verification report
Methods, equipment, conditions, uncertainty inputs, measured results, model correlation, and open issues.
Next-build package
Design changes, risk disposition, acceptance updates, supplier actions, cost drivers, and transfer recommendations.
06Controlled 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.
07Qualification questions
Questions engineering teams ask before engaging.
01Can PAO build the prototype rather than only provide a design?
Yes. PAO can coordinate custom optics and mechanical parts, integrate the optical subsystem, align and calibrate it, execute the agreed verification plan, and deliver hardware with an engineering record.
02Can you start from our existing Zemax, Code V, CAD, or bench design?
Yes. Existing models, drawings, CAD, test data, images, and hardware can be reviewed. The first step is to establish configuration, assumptions, interfaces, and the gap to the required product behavior.
03How do you prevent a prototype from becoming a dead end?
The team defines which parts are temporary, which interfaces are product intent, how results will be measured, and what documentation the next build requires before fabrication begins.
04What determines prototype cost and schedule?
The largest drivers are prototype fidelity, number and complexity of custom optical parts, supplier lead times, optomechanical complexity, assembly and calibration effort, required test equipment, iteration allowance, and whether usable models and requirements already exist.
05Can the program start under an NDA?
Yes. A non-confidential intake can establish fit first. Models, CAD, drawings, images, test data, supplier information, and failure analysis can then move through an agreed confidential channel.
06Can PAO transfer the prototype to our manufacturer?
Yes. The transfer package can include controlled models and drawings, BOM and specifications, supplier clarifications, assembly and alignment instructions, calibration procedures, acceptance methods, known deviations, and support through the receiving build.
09Start a conversation
Tell us what the prototype must prove and when the decision is needed.
Share current requirements, models, CAD, images, test data, hardware status, and the technical decision the prototype needs to support.