Resolve the system before locking the parts.
Requirements, first-order models, architecture trades, lens and illumination design, detector interfaces, performance budgets, stray light, and tolerancing.
Silicon Valley optical engineeringPalo Alto, California
Bay Area service
Custom optical engineering for Silicon Valley product teams.
Palo Alto Optics provides custom optical design, optomechanical engineering, prototype development, and manufacturing transfer for Silicon Valley and U.S. product teams. PAO is a fit when imaging, illumination, sensing, laser, display, or packaging risk is blocking a product decision, and can deliver models, tolerance analyses, drawings, prototype hardware, verification evidence, and supplier-ready documentation.
01Engineering scope
One technical partner across optical design, mechanics, prototype hardware, and transfer.
Make optics and mechanics converge.
Mounts, alignment strategy, packaging, thermal and structural effects, CAD interfaces, calibration provisions, drawings, and supplier-ready specifications.
Continue through build and verification.
Custom component sourcing, prototype coordination, assembly, alignment, calibration, test planning, acceptance evidence, and production transfer support.
02Project fit
Use PAO when optical risk crosses design, hardware, and supplier boundaries.
PAO can enter before architecture is fixed, during detailed design, at prototype integration, or when existing hardware is missing its requirement.
A product decision needs optics input
Architecture, sensor, source, package, performance, cost, or schedule is being decided and optical risk must be made explicit.
A prototype needs hands-on closure
The team needs local design reviews, hardware handoffs, alignment, calibration, measurement, or failure isolation.
An existing program needs recovery
PAO can review current models, CAD, parts, images, and test data, then define a focused work package without restarting the program.
ENGINEERING DECISION TABLE
Information that determines the right first work package.
| Input condition | Key metric | Design choice | Risk if unresolved |
|---|---|---|---|
| Application and machine decision | Required optical or product-level outcome | Imaging, illumination, sensing, laser, or display architecture | The optical subsystem is optimized for the wrong product requirement. |
| Field, wavelength, package, and environment | Resolution, signal, stability, and usable margin | Optical form, detector or source, materials, coatings, and mechanics | A nominal model fails after packaging or environmental exposure. |
| Program stage and current evidence | Highest unresolved technical risk | Review, feasibility study, detailed design, prototype, or recovery | The team builds hardware before the critical assumption is tested. |
| Volume, cost, schedule, and supplier path | Tolerance yield, lead time, acceptance capability | Prototype versus production processes and transfer package | A successful first unit cannot be reproduced economically. |
SELECTED ENGINEERING EVIDENCE
Documented scope and a clear disclosure boundary.
Prior-role records demonstrate relevant engineering methods but are not presented as PAO customer engagements. New PAO work is verified against the agreed configuration and acceptance plan.
Custom optical systems
- Scope
- Documented work across custom imaging, projection, laser, and inspection optics, including design, tolerancing, supplier interfaces, and test.
- Verification
- Metrology planning, image tests, acceptance limits, and model-to-test comparison.
- Boundary
- Customer identities, exact specifications, quantities, and confidential outcomes are withheld.
New PAO project evidence
- Scope
- Requirements trace, controlled models and drawings, as-built configuration, calibration state, and transfer documentation.
- Verification
- Test methods, conditions, equipment, uncertainty inputs, measured results, and open issues remain linked.
- Boundary
- Results, schedules, costs, and publication rights are specific to the agreed project scope and NDA.
03Local product sectors
Built for programs where optical risk can delay the product.
Engagements are scoped around the actual technical problem rather than a prepackaged consulting menu.
Robotics and machine vision
Imaging, active illumination, calibration, sensor and lens selection, packaging, and verification for automation and intelligent machines.
Semiconductor equipment
UV illumination, projection, inspection, alignment, DMD-based architectures, stray-light control, and optomechanical integration.
Automotive and mobility
LiDAR transmit and receive paths, camera optics, HUD projection, environmental packaging, calibration, and system validation.
Wearables, displays, and instruments
Near-eye display optics, compact imaging, sensing, biomedical instruments, and other products where optical performance must fit a constrained package.
04Working sequence
Start with the unresolved risk. Build only after the decisions are explicit.
The work can begin at any stage, including an independent review of an existing design or a focused recovery effort for a prototype that is not meeting requirements.
- 01
Frame
Clarify the use case, interfaces, envelope, performance target, schedule, and largest technical unknowns.
- 02
Trade
Compare feasible architectures and expose sensitivity, cost, packaging, and sourcing risks before detailed design.
- 03
Design
Develop the optical and mechanical system, tolerances, drawings, interfaces, and verification approach together.
- 04
Prototype
Coordinate custom parts, assemble and align hardware, measure performance, and close the gap between model and test.
- 05
Transfer
Deliver controlled documentation, acceptance criteria, supplier communication, and support for repeatable builds.
05Local collaboration
Palo Alto based, with practical access across the Bay Area.
Serving product teams in Palo Alto, Mountain View, Sunnyvale, Santa Clara, San Jose, San Francisco, and the wider Bay Area.
In-person technical reviews, hardware handoffs, and integration support can be arranged when they improve the program.
Confidential requirements can move to an agreed NDA channel before detailed design files or sensitive program information are exchanged.
A useful first inquiry includes the application, wavelength or spectral range, envelope, key performance target, program stage, and schedule.
06Procurement questions
What teams need to know before engaging PAO.
01Do you only work with companies in Silicon Valley?
No. PAO supports optical programs across the United States. Bay Area teams can also use in-person technical reviews, hardware handoffs, and integration support when those activities reduce program risk.
02What does an initial optical engineering engagement cost?
Cost depends on the decision and evidence required. A focused review or feasibility study is smaller than detailed design, custom prototype hardware, and manufacturing transfer. PAO first defines the work package, assumptions, deliverables, schedule, and commercial basis.
03Can PAO take over an existing design or failing prototype?
Yes. Existing Zemax or CODE V models, CAD, drawings, components, images, test data, and failure observations can be reviewed. The first output is a controlled baseline, gap assessment, and prioritized recovery plan.
04Can we discuss the project under an NDA?
Yes. The first conversation can remain non-confidential, then sensitive requirements, models, drawings, supplier details, and data can move through an agreed NDA channel.
05Do you build prototypes or only provide consulting?
PAO can continue through component sourcing, optomechanical integration, assembly, alignment, calibration, verification, and delivery of prototype hardware with an engineering record.
06Can you support manufacturing after the prototype?
Yes. Work can include supplier-ready models and drawings, tolerance and acceptance definitions, assembly and calibration instructions, supplier review, build issue closure, and support for transfer to the customer's manufacturing path.