Creating waveguides requires tight control over process conditions so the final structure matches the intended design.
Achieving this level of accuracy depends on advanced machinery that’s capable of positioning components precisely and enabling repeatable results.
We use a mix of commercial and custom-built equipment developed specifically for waveguide manufacturing. Our equipment engineering team designs them, and our fabrication team uses them to create our waveguides.
Here’s how our teams design, build, and use the machines behind our waveguide manufacturing process.
Step 1: Identify Where Custom Machinery is Needed
Waveguide manufacturing involves many specialized steps, including material preparation and inspection. At each stage, our teams evaluate whether commercial equipment can meet our high standards for accuracy, stability, and repeatability.
In many cases, industry-standard machines can handle part of the work. But some of our waveguide processes demand capabilities those systems were not designed to handle. In those instances, our equipment engineering team works with our fabrication experts to identify where custom equipment can improve performance or process control.
Step 2: Translate Internal Needs into Machine Requirements
Once a need for new or modified equipment is identified, the teams translate process goals into detailed machine requirements.
Define Technical Requirements
First, the teams determine what the machine needs to do, such as gluing, aligning, or curing materials. The teams then define the key requirements the machine must meet, which could be things like motion stability or position accuracy.
Establishing these specifications early helps ensure the final equipment design aligns with our major manufacturing goals and targets.
Adapt or Build
With the technical requirements defined, the equipment engineering team evaluates whether an existing machine can be modified or whether a new tool should be built from scratch.
Some commercial tools can be adapted with minor mechanical or software adjustments. Others require fully customized equipment designed specifically for our manufacturing process.
Step 3: Design Equipment with Production in Mind
When customization is needed and the approach is defined, the equipment engineering team begins designing and building the machine. These designs must support both current development work and future improvements as waveguide designs and manufacturing processes continue to evolve.
Several key factors shape these designs:
Process Integration
The machine must fit seamlessly into the broader manufacturing workflow, connecting smoothly with upstream and downstream steps.
Positioning Control and Stability
Waveguide processes often depend on extremely precise alignment. Mechanical structures and motion systems are designed to maintain stable operating conditions.
Material Handling
Waveguide substrates and coatings must be moved and positioned carefully to avoid damage or contamination.
Production Readiness
As designs and demand mature, machines should be capable of handling higher volumes while maintaining consistent results and yields.
Designing with these factors in mind helps the team ensure new machines transition smoothly from development environments into the production workflow.
Step 4: Validate, Iterate, and Release
Before entering production, each machine is tested against the performance criteria defined earlier in the process. The team confirms the system can maintain consistent results across repeated runs.
Engineers may refine mechanical components or adjust software based on testing results, allowing machines to evolve alongside the manufacturing process and the waveguides they produce.
Together, these efforts ensure that our manufacturing equipment evolves alongside our waveguide technology. By combining internal expertise with purpose-built tools, our teams are able to maintain the precision, consistency, and scalability required to support ongoing innovation in waveguide design and production.
Learn more about our Waveguide Manufacturing Process.