Positioning and alignment strategy in freeform mirror-based systems

System performance in optical, optomechanical, and optoelectronic systems is directly dependent on the precision level of
positioning and alignment of the components. The location-specific placing of the optics plays a crucial role in limiting the energy loss
in the Head-up display (HUD) system. The requirements for positioning and optical alignment become more stringent as the freeform
optical elements, their functional and mounting surfaces with size and orientation become complicated along with the packaging
restrictions get more severe. A simple sequential positioning and alignment technique that maintains the performance of HUD
systems as per the required level is outlined. Three processes are involved in controlling the precision level i.e., (1) string-based
mapping that provides accuracy upto 100’s µm, (2) coordinate-measuring machine-based adjustments that offer position accuracy
under 10’s µm and (3) laser-based approach to maintain sub-micron positional accuracy. In spite of having certain challengesin terms
of component handling and fixturing, this newly developed sequential stationing method (SSM) opens up new research directions
that are inevitable for small-, mid-, and large-scale system integration.