Active Alignment with UV System Solution
The demands placed on modern optical sensors — such as cameras, LiDAR systems, and image processing units — are constantly increasing. To ensure precise adjustment and permanently stable positioning of these sensitive components, innovative manufacturing processes rely on active alignment in combination with high-performance UV adhesives and precise LED curing.
In active alignment, camera or sensor components are optically adjusted in real time during the assembly process. Final fixation is achieved using light-curing adhesives, which are cured immediately after optimal alignment. This process ensures that the components remain precisely positioned in relation to each other – a prerequisite for high image quality, low reject rates, and fast production cycles.
UV Adhesives for Active Alignment
UV adhesives offer decisive advantages in active alignment applications:
- Fast curing for short cycle times
- High positional stability even with minimal shrinkage
- Low outgassing behavior, ideal for optically sensitive areas
- Adjustable viscosity for precise dosing
- Combined curing mechanisms (UV + heat) for hard-to-reach bonding points
Hoenle’s Vitralit® adhesives, specially developed for active alignment, meet all the requirements of modern sensor manufacturing. They enable primary UV curing and offer secondary thermal post-curing if required – ideal for applications with shadow zones or complex component geometries.
These products are specially tailored to the requirements of active alignment processes and ensure permanent and precise bonding.
UV adhesives with low shrinkage are the perfect solution for active alignment
Special lenses on the LED heads ensure higher intensities
LED-UV Curing Equipment For Active Alignment
UV curing is a central component of the active alignment process. With its bluepoint LED systems, Hoenle offers an ideal solution for the precise curing of adhesives – even in tight spaces and for complex gap bonding.
The new linear optics deliver up to 7,000 mW/cm² intensity on an area of only 10 × 2 mm – perfect for narrow bonding gaps. Multiple LED heads can be arranged modularly around the component, enabling homogeneous illumination even for ring gap bonding.
Advantages of the new LED systems:
- Retrofittable for existing bluepoint LED heads
- Passive cooling for easy integration
- Flexible arrangement for complex components such as LiDAR sensors
The precision of the bonding process is directly reflected in the optical performance. Quality control is therefore often carried out using the modulation transfer function (MTF). This tests how well the system can reproduce fine details – direct proof of the stability and accuracy of the bond.
For active alignment applications, the combination of specialized UV adhesives and high-precision LED curing is the key to reliable, high-resolution sensors. Hoenle offers tailor-made options for your application – from adhesive selection to the optimal curing solution.
Whether camera modules, LiDAR systems, or optical assemblies in the automotive, electronics, or robotics industries—there is no one-size-fits-all solution. That’s why Hoenle offers a wide selection of UV adhesives, including:
| Adhesive | Usage | Viscosity [mPas] | Base | Curing * | Special Properties |
|---|---|---|---|---|---|
|
35,000-50,000 (Rheometer, 25 °C, 10s^-1) | Acrylate | UV/VIS |
|
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45,000 (Rheometer, 25 °C, 10s^-1) | Epoxy | UV/secondary heat cure |
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|
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40,000 (Rheometer, 25°C, 10s^-1) | Epoxy | UV/VIS |
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*UV = 320 – 390 nm VIS = 405 nm
Find out more about our Hoenle bluepoint LED eco.
Contact And Support
Do you have any questions or need support for our active alignment solutions? We are happy to help you.
