Optical tolerance analysis is a very important step in optical systems development. It ensures that appropriate optical performances will be achieved considering all the manufacturing errors involved in the assembly. To perform an accurate tolerance analysis, a realistic optomechanical tolerance model and appropriate perturbations simulation are required in the optical design code. Most of the time, optomechanical lens mounting is not taken into account accurately in classical optical tolerancing method. To improve optical system tolerancing process, an integrated opto-mechanical tolerance analysis is proposed. This paper first describes typical tolerancing process and iteration performed between optical designers and optomechanical engineers in the development of optical systems. Then, the optomechanical tolerance analysis that involves interactions between lenses and mounts, as well as manufacturing errors is presented. Simulation methods to consolidate optical and optomechanical tolerance analysis are discussed. Finally, an integrated optomechanical tolerance analysis is described, and a new optomechanical tolerancing software is introduced. The intent of this new modeling method is to perform accurate optical simulations that are representative of the optomechanical mounting and centering methods. This result in a more efficient allocation of the tolerances and a more accurate prediction of the optical system performances.
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