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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Design of the luminescence test bench

Before designing the bench, PISÉO’s experts specified the radiometric performances to be achieved on the samples to be tested, and defined the methods for recording the evolution of luminescence over time after being charged with energy. We also specified functionalities such as the control of light sources that make it possible to create the desired energy irradiance and light spectrum depending on the type of sample tested. We then evaluated the market offering of UV and visible LEDs and selected components likely to allow them (via appropriate combinations) to create radiation similar to that of the sun. Once all the requirements were defined and the concept imagined, we proceeded to size the multi-spectral LED illuminator through calculation and optical simulation.

The bench was then designed in detail. The mechanical part was entirely designed at PISÉO using SolidWorks CAD software. Furthermore, the LED illuminator integrated into the bench, which requires a significant amount of power per unit of surface area, was the subject of a thermal study. The results of this study led to the definition of the cooling components (radiator, fans). The electronic part was developed by a partner who has the means based on PISÉO’s specifications. The video-luminance camera, which makes it possible to record luminance levels and their uniformity over time, was calibrated equipment already available in the PISÉO laboratory. The image processing software is that of the camera.

Creation and validation of the luminescence test bench

Once the components and subassemblies were specified and supplied, the test bench was assembled and tested in the PISÉO laboratory. A detailed test plan was defined to verify performance and functionality against the initial objectives of the bench. Measurements of irradiance and spectral distribution were carried out using the Instrument Systems CAS 140D spectroradiometer, calibrated under ISO 17025 accreditation from the PISÉO laboratory. Finally, the repeatability and reproducibility tests carried out led to the validation of the test bench.

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The complexity of this bench was linked to the particularities of the components to be tested, resulting in tight technological constraints. The design and installation of such a bench calls for in-depth knowledge in several fields including physical interactions between light and matter, optical technologies and manipulation of precision optical components and laser technologies.

This customer, not having the skills in optical test bench engineering, called on PISÉO to make one. The project was segmented into three parts: specification, design, and construction and validation.

Laser light has very specific properties, such as a precise wavelength and coherent and directed light emission. The components to be tested, due to their structure, respond differently to light stimuli depending on these properties. The measurement bench must therefore be able to control quantities such as power, beam direction, polarization, modulation and time profile.

Design and assembly of the laser test bench

From the specification and the architecture, designing the bench involved sizing all the structures and electro-optical components necessary in detail while ensuring a guarantee of performance, robustness, and reliability. This guarantee is highly dependent on the experience of the designers and the depth of their work. PISÉO’s optical bench experts can assess the critical parameters of optical, opto-mechanical, and electro-optical components affecting performance or conditions of use. Several technical details of optical components available from specialized manufacturers have been verified by a direct approach to suppliers, reinforced where necessary by optical calculations and simulations. This approach justifies the choices made as well as discarding components that had otherwise seemed to be suitable.

PISÉO also ensured that the laser measurement bench meets the appropriate safety standards, particularly regarding laser risk. As specialists in optical risk induced by artificial light sources, PISÉO engineers and technicians are trained in controlling the laser risk and able to define the protocols for handling the bench in safe conditions, both during the design phase and when used over time.

Performance characterization in the laboratory

This laser test bench has been validated on the basis of three levels of tests and performance characterization:

– Characterization of the beam produced at the different stages of its shaping. This approach is based on PISÉO’s precise and flexible measuring instruments including spectroradiometers, profile projectors, calibrated reference sensors, power meters, transimpedance amplifiers and high frequency oscilloscope. They make it possible to appreciate the multiple characteristics of the beam, such as the power, pulse timing, polarization, and direction of the beam.

– Calculation of uncertainties by analytical methods, justifying the measurement precision of the various parameters.

– Practical statistical methods including Gage Repeatability and Reproducibility applied to the different conditions of use of the test bench.

The characterization stage thus made it possible to optimize the settings and guarantee the required alignment of the optical part of the bench, to define the parameters for acquiring the signals measured, to perfect the test procedures, and to specify the checklist for verifying the proper functioning of the test bench prior to a test campaign.

Uncertainty calculations ultimately make it possible to give confidence to the measured values produced during production tests.

Practical validations show the level of robustness of the measurements carried out under laboratory conditions.

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Test benches are essential tools for measuring the optical performance of medical devices such as illumination systems used particularly in medical applications, more specifically surgery.

After devising a light projector integrated into an endoscope-type surgical robot, the customer wanted to measure the relative illumination delivered by this projector during its manufacture. PISÉO designed and produced a dedicated optical measurement bench for this purpose.

To meet the customer’s needs, PISÉO designed the measurement bench  to manage the plurality of lighting profiles produced by the projector. The projector uses LED-type light sources that have various emission lobe angles, but also laser-type light sources whose beam is collimated. PISÉO therefore had to consider all the wavelengths between 400 nm and 850 nm emitted by these different light sources to design and build this test bench.

Specification and opto-mechanical design of the test bench

To meet the customer’s expectations, the PISÉO experts imagined an imaging system capable of reading the lighting profiles projected on a diffusing surface. The profiles measured in this way make it possible to verify in a simple and robust way, in production, that the light emission profiles of the projector comply with the characteristics expected of the projector once integrated. They then specified the architecture of the bench and its components including camera, lens, mechanical and electrical interfaces, then carried out the detailed design.

Validation of the test bench

Once the measurement bench was assembled, PISÉO engineers carried out a series of tests to check its performance.

First, they did geometric and radiometric calibrations. The verifications focused on the calculations of the illumination profiles produced by a diffuse light source and by a collimated light source, which were compared with the profiles measured by devices in the PISÉO laboratory. The difference observed was less than the precision required by the customer, so the measuring bench was validated.

At the end of these tests, PISÉO recorded the geometric and radiometric calibrations in the measuring bench. The engineers set up management by serial number to manage the different copies of the measuring bench. They also compiled a user manual, a manufacturing file and a technical report gathering all the results of the tests carried out on the bench to allow the customer to understand the device’s performance.

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