Ansys Zemax Simulation for Optical Design Optimization

This case study details the application of Ansys Zemax OpticStudio by Nordson TEST & INSPECTION to enhance their optical design process. The document outlines the challenges faced during sensor development, particularly concerns regarding the optimization of input variable settings without extensive experimental iteration. To address these challenges, Nordson TEST & INSPECTION utilized Zemax for ray tracing and Matlab for data management, allowing for a comprehensive trade space analysis. This analysis enabled the identification of variable settings that maximized depth of field while minimizing focus position error. The case study also highlights the benefits of incorporating high-yield optimization techniques, which have significantly reduced tolerancing time from a 50/50 split to approximately 75/25. Additionally, it notes that the simulation method saved considerable time during the design process, with estimates of saving a week for each new sensor developed. Overall, the case study illustrates the effectiveness of simulation in improving design efficiency and product development timelines.