What is active alignment?
Active alignment refers to the process of fine-tuning or precisely aligning components, typically optical or mechanical systems, while the system is actively operating. This method is commonly used in the manufacturing and assembly of high-precision devices, such as cameras, sensors, and optical instruments.
In contrast to “passive alignment,” where components are assembled based on predetermined measurements or templates, active alignment adjusts the components in real-time while monitoring the system’s performance to achieve optimal results.
For example, in an optical system, active alignment may involve adjusting lenses or mirrors while measuring factors like beam intensity or focus to ensure that the system performs at its best. This method is particularly useful for applications where even tiny misalignments can cause significant performance degradation, such as in fiber optics, imaging systems, and laser setups.
Active alignment adhesives are specialized materials used in high-precision assembly processes where components are aligned in real-time and then bonded or fixed in place once the desired alignment is achieved. These adhesives play a crucial role in industries like optics, photonics, electronics, and automotive systems where precise positioning and stability of components are essential.
Key Characteristics of Active Alignment Adhesives:
Fast Curing: Many active alignment adhesives cure quickly under specific conditions (such as UV light, heat, or moisture) to reduce assembly time and ensure the components remain in the exact position once aligned.
Low Shrinkage: To maintain precise alignment, these adhesives are engineered to have minimal shrinkage during curing, preventing any shift in the components after bonding.
High Precision: They provide strong bonding strength while allowing precise positioning during the assembly process, ensuring that minute adjustments can be made without losing alignment accuracy.
Thermal and Mechanical Stability: Active alignment adhesives are designed to withstand thermal expansion, contraction, and mechanical stresses, ensuring long-term stability in challenging environments.
Applications
Optical Systems: Used to bond lenses, sensors, mirrors, and other optical components with precise alignment in applications like cameras, projectors, and fiber optic assemblies.
Photonics and Lasers: Employed in the alignment of lasers, detectors, and fiber optic components where tiny misalignments can significantly affect performance.
Automotive Sensors: Utilized in advanced driver-assistance systems (ADAS) sensors and cameras, where exact positioning is critical for accurate data collection and functioning.
Electronics: Used in smartphones, tablets, and other devices where small misalignments can degrade performance, especially in high-resolution displays and camera modules.
These adhesives offer a combination of ease of use, precise bonding, and durability, which is why they are preferred in applications that require high-performance alignment solutions.
FLASHBOND UV-3720 is Epoxyset’s leading adhesive for active alignment applications. It is a UV/Heat cure system offering low CTE, fast cure, high stability, and is customizable.
