How PISÉO transforms a laboratory setup into reliable industrial equipment for Non-Destructive Testing

In the semiconductor and integrated photonics industries, a component’s final performance depends directly on the quality of the material used. When a crystal defect is detected too late, after costly manufacturing steps, the industrial losses become irrecoverable.

Identifying these defects early on is therefore a major strategic challenge. However, this requires a measurement system capable of moving beyond the experimental framework to become a reliable, reproducible and usable tool in an industrial environment.

It is precisely at this critical juncture, the transition from scientific proof to industrial equipment, that PISÉO adds value.

Metrology based on nonlinear reflectometry

The solution is based on an advanced nonlinear reflectometry technique that utilizes second harmonic generation (SHG).

The material is illuminated with an infrared femtosecond laser and the optical response generated at twice the fundamental frequency is analyzed. The observed variations, combined with the analysis of polarization states, reveal signatures directly linked to the crystalline structure.

Unlike conventional optical approaches, this method allows for the detection of invisible structural defects while remaining completely non-destructive.

PISÉO, a partner in the industrialization of photonic technologies

Transforming a scientific innovation into a sustainable industrial advantage requires much more than just optical expertise. It requires a combined mastery of optics, precision mechanics, and systems engineering.

This is precisely the role that PISÉO plays for its industrial partners: designing, securing, and industrializing complex optical systems capable of operating reliably in demanding environments.

Choosing PISÉO means relying on a partner capable of transforming laboratory-based technology into operational, robust, and durable industrial equipment.

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VCSEL LASER source for electro-optical testing

Electro-optical test benches for imaging sensors usually use LEDs.

For our client, the operating frequency requirements were such that only LASER diode-type sources – in particular VCSELs – had the necessary temporal dynamics to meet them.

With the help of our partner, Yole Group, PISÉO’s experts were able to quickly identify the VCSEL die suppliers in the United States and Asia that were likely to meet the client’s needs. The selected component was assembled by our partner, Serma Microelectronics, using microelectronics techniques, and then extensively tested by PISÉO in our optical laboratory.

Finally, since these components are generally used for optical fiber telecommunications links, our choice to control them quickly fell to a telecom-type driver.

Optical design and engineering

LASER sources, which are used for their dynamic temporal response, have very specific emission profiles requiring the design of a specific optical system to meet the needs of the application. To this end, our engineers, specializing in optical design and engineering, have defined a very precise multi-stage system that enables PISÉO to create controlled lighting from the point-of-view of spatial and incidence characteristics.

To do this, we first characterized the source beam using a beam profiler in the PISÉO optical laboratory.

Based on the measurement results, we then specified a system integrating optical geometry and materials to achieve the desired objectives. Our engineers also used Zemax Optics Studio software to perform this work.

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Creation and validation of modules in several copies

Several electro-optical test modules were thus assembled in a clean room, and then calibrated and tested in the PISÉO optical laboratory according to a rigorous protocol and test plan. Numerous R&R, reliability, and lifespan tests were carried out to allow us, in agreement with the customer, to fully validate the design and manufacturing of the modules.

PISÉO’s customers trust our experts for the development and manufacturing of complex, innovative, and robust optical test benches.

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Assembly & validation of the bench

The characterization bench was entirely assembled at the PISÉO optical laboratory. Numerous electro-optical tests were rigorously carried out to verify the reproducibility and repeatability (R&R) of the measurements. Uncertainty calculations were also carried out to assess the precision achieved by the measurements. The results of this work enabled the validation of the bench in the laboratory.

Because this characterization bench must be integrated into a wafer tester, PISÉO’s engineers ensured the assembly and validation of the bench in a clean room at the client’s site. We also trained their engineers in the use of the bench.

PISÉO’s customers trust our experts for the development and manufacture of complex, ultra-precise optical characterization benches.

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Optical design and engineering

Developing HMIs that integrate LED-based lighting functions requires very sophisticated optical engineering. These HMIs are often embedded in devices with complex shapes and must still meet important visual ergonomic objectives. In the case of this client, the shape of the pictograms and the limited size represented a real challenge. By mobilizing their extensive knowledge of optical technologies and systems, PISÉO’s optical engineers leveraged their creativity and simulation resources, such as LightTools software, to define an optimal technical solution.

HMI light guide

PISÉO’s optical engineers created several original and optimized light guides to meet the client’s needs. After considering the mechanical constraints of the system, they defined the very elaborate geometries that maximized the LED’s incoming flux in the optical guides and precisely controlled the light extraction. Thanks to these specific geometries, the client’s HMIs have no hot spots or light leaks. The light guide solutions developed by PISÉO also make strong contrasts and homogeneous color mixtures possible.

Validation of display quality on an HMI prototype

A prototype was produced by the client based on data provided by PISÉO. Its performance was characterized in our photometry laboratory to verify that the display quality corresponded to the simulations carried out during the design. Luminance measurements and mappings were carried out with a highly resolved video luminance meter. These tests made it possible to validate the work carried out by PISÉO’s optical engineers.

The findings of this project highlight the significant impact of optical engineering combined with cutting-edge simulation methods and rigorous photometry testing. Just like our satisfied client, you too can opt for excellence by calling on the unrivaled expertise of PISÉO engineers to design HMIs that offer exceptional display quality.

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Many applications now use VCSELs: automotive radar, facial recognition … Widely used in the automotive industry and in smartphones, its manufacture and integration into systems require special skills, skills now mastered by PISÉO.

What are VCSELs?

VCSELs are semiconductor laser diodes that emit a light beam perpendicular to their surface. In physical terms, they are vertical stacks of semiconductor materials forming resonance cavities within which a laser-like light is generated as soon as a weak current passes through them.

Depending on the specific semiconductor materials used in the product, VCSELs can emit over a large portion of the electromagnetic spectrum, including ultraviolet, visible, and infrared. Most of its applications, however, are in ultraviolet and infrared.

What are the advantages of VCSELs over conventional LEDs?

? VCSELs can operate at high frequencies, hundreds of megahertz.

? They have a very narrow spectral band, making them more efficient in specific applications such as fiber optics.

? Their wavelengths are not very temperature-dependent.

? They are characterized by narrow light beams.

What are VCSELs used for today?

The VCSEL market is currently booming. According to Yole Développement (“VCSELs Technology and Market Trends 2021” report), a growth of 13.6% per year is forecasted until 2026. Currently, VCSELs are undergoing major technological changes, which will also create a new balance between manufacturers. Market size expected to reach $ 2.4 billion in 2023.

After approximately 40 years of technological development, VCSELs are now used in many applications, including consumer products.

Some examples :

In the general public

VCSELs are widely used in laser ranging. The distance to an object is calculated from the time between the light’s emission and its return from an object. This is used in, for example:

? the automotive sector: LIDAR, radar, driver monitoring, autonomous driving, etc.

? the smartphone industry: autofocus, facial recognition, etc.

In high-tech industry

Some examples :

? data transmission by optical fiber

? medical sector: neurostimulation and optical coherence tomography (OCT), blood flow measurement, ophthalmology, etc.

? industrial sector: data transmission system, industrial heating, security by video surveillance, etc.

PISEO ’s expertise

PISEO has been aware of the importance of this technology for many sectors and is constantly on the lookout for innovative illumination sources in the market. Its experts have inventoried and analyzed all the manufacturers of VCSELs. They have studied their qualities, their strengths, their weaknesses, and the advantages and disadvantages of each product and its manufacturer. This provides an unbiased benchmark that allows it to be a real source of practical information to its customers in defining the best component for each use case.

PISEO ‘s goal is to help its customers use VCSELs through product studies, development, integration of technology into products, design of systems that use them, characterization of optical performance, qualification, manufacturing monitoring, etc..

PISEO, and its team of 16 experts, imagines, designs, and manufactures systems using VCSELs for its customers and all types of applications. In particular, they invented, developed, produced, and qualified a system, unique in the world, for producing a very high-frequency light beam to perform useful tests for one of its customers, a world leader in microelectronics. Bare VCSELs are purchased in the United States and “packaged” by SERMA Microelectronics. The components are then mounted on a specific electronic card, designed by the company E.RE.C.A. It is assembled in a mechanical module designed and produced by the company E.F.S. Numerous temporal and photometric operational tests in a climatic chamber have been conducted within PISEO ’s laboratory in Vénissieux.

In this way, the module is qualified, its reliability assured, before delivery to the customer.

As a true conductor and architect of the system, PISEO supervised the three essential stages of the project: to specify, manufacture the subassemblies and assemble the product, and validate this innovative module created in a little serie.

An optical-photonics innovation center, PISEO has the internal resources to analyze light-matter interactions and then imagine, develop, build, and validate optimized industrial systems that integrate VCSEL.

In addition, its optical metrology test lab, partially accredited by COFRAC (scope available on www.cofrac.fr), allows the performance of these products to be tested according to various parameters.

Reports related to this article :

VCSELs – Technology and Market Trends 2021 (Yole Développement)

3D Imaging and Sensing – Technology and Market Trends 2021 (Yole Développement)

Apple iPad Pro LiDAR Module (System Plus Consulting)

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At the request of their Client, PISEO experts have carried out cost reduction work by modifying the architecture of the module and by adapting the microlenses of the camera lens.

Optical redesign

• Definition of the optical system archictecture for both illumination and detection functions.
• Component search and selection.
• Optical simulations by use of ZEMAX.
• Spectral optimization.
• Optical design of micro-lenses.
• Costing.
• Support to customer for the selection of the camera module maker, audit in Taiwan.

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These inspections require heavy equipment and put workers at risk

This is the way visual inspection procedures have been performed since the beginnings of civil aviation.

DONECLE, a French company, has strong expertise in aircraft maintenance processes, drone robotics, automation and “deep learning” computer vision algorithms.

This company has, therefore, seized this opportunity to revolutionize the way inspections have been carried out over the past 40 years.

It was for this ambitious project that DONECLE turned to the experts at PISEO for assistance in the design of the on-board inspection camera illuminator.

Design of the on-board inspection camera illuminator

Machine vision systems are more and more widespread. Indeed, cameras and ready-to-use lenses are readily available on the market.

However, software to process the captured images, even very sophisticated ones, does not always succeed in sufficiently discriminating between the scenes. This is often due to poorly adapted lighting.

Well-designed LED lighting can compensate for problems with lens vignetting, colorimetry, and scene uniformity.

PISEO, therefore, supported this company in the design of a particularly efficient lighting system.

The aim was to help compensate for vignetting and colorimetry issues due to the camera lens and thus the overall performance of the inspection system.

Thanks to this product and PISEO’s support, DONECLE is now the worldwide leader of automated aircraft visual inspection based on drone technology. The company offers a unique solution combining a 100% automated drone with advanced image analysis algorithms for the detection of damage to the exterior surface of aircraft.

The illuminator developed with PISEO now allows it to guarantee consistent image quality, regardless of exterior light conditions.

on-board inspection camera illuminator

· Search for suitable LED components.

· Optical design of potential solutions.

. Simulation performance comparisons with Light Tools software

· Prototyping of the chosen solution.

· Characterization of the optical performance of the prototype in the PISEO lab.

Illuminator for on-board inspection camera

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