Active Alignment Camera Modules & Optical Devices

What is Active Alignment for Camera Modules

Active alignment is a high‑precision process used during the assembly of multi‑element optical systems, such as camera modules, to ensure optimal image quality. Unlike passive alignment, which relies on mechanical tolerances, active alignment dynamically adjusts the lens position while monitoring real‑time image feedback.

This technique ensures micron‑level accuracy for parameters such as focus, center, tilt, and rotation. It is essential in mass production of advanced imaging systems—including smartphones, connected devices, automotive ADAS, medical devices, and industrial vision—where performance and consistency matter.

The Assembly of Camera Modules Requires Precision and Perfection

Every step must be executed with care to avoid flaws or defects. Averna ensures high‑quality alignment for all types of cameras used across hundreds of applications—from cellphones to autonomous vehicles. The same technology applies to LED or laser‑based systems, including multi‑beam headlights.

Our active alignment machine offers high quality and flexibility with minimal retooling. Thanks to smart system testing, we guarantee crisp images through precise lens‑to‑sensor alignment and algorithms supporting large fields of view and boresight optimization.

Our expertise covers semi‑ and fully automated test equipment as well as small and bench‑top prototype systems, allowing customers to optimize designs before locking them in.

Why Choose Averna for Active Optical Alignment Assembly

Poor alignment can lead to blurry images, inaccurate depth perception, and major quality issues—especially for ADAS, AR/VR/MR, or mobile devices. Passive alignment often lacks precision, repeatability, and speed.

That’s where Averna makes the difference.

We help manufacturers overcome challenges such as:

Micron‑level accuracy with low process variability

High throughput without compromising image quality

Stability under thermal or mechanical stress

Fast changeover for mixed product lines

With over two decades of experience in vision systems and automation, we deliver robust, production‑ready platforms. Our integrated approach combines optical metrology, image processing, robotics, and proprietary alignment algorithms for consistent, top‑tier performance.

Expertise Through the Entire Lifecycle

From development to mass production, Averna supports every stage of your camera module’s lifecycle. We offer prototyping tools, semi‑automated solutions for ramp‑up, and fully automated platforms for high‑volume production.

Key Benefits of Averna’s Active Alignment Solutions

Higher image quality through precise optical alignment

Faster assembly cycles

High manufacturing yield

Compact equipment for limited production space

Minimal operator involvement

Flexible for small lens sizes

The Active Alignment Process for Camera Modules

Active alignment is a multi-step process designed to ensure optimal optical performance and mechanical stability in camera modules. Each phase plays a key role in delivering high‑quality images, especially in applications requiring precision and reliability.

Preparation

All optical and electronic components undergo rigorous vision inspection to ensure they are defect‑free before assembly. Every surface must be cleaned, treated, tested and verified. The equipment checks lens quality and performs chip tests for hot, dark and dead pixels, along with current, pixel response and uniformity measurements.

Dispensing

Dispensing is executed accurately to avoid glue‑beading deformities. Multiple dispensing techniques (jetting, volumetric) are supported, with controlled parameters to compensate for glue viscosity variations. Machine vision measures dispensing position and validates results early.

Alignment

Alignment takes place in a clean environment using a fully automated multi‑axis motion system. Using projections and target verification, components are assembled with micrometer accuracy, following NEN12233 standards or Averna‑specific alignment algorithms.

UV‑Curing

UV curing is performed within the alignment environment. Because curing can shift components, multiple curing phases are integrated and continuously monitored. Thermal curing steps ensure structural solidity.

Validation

The assembled module is re‑validated after alignment. Every step can introduce defects, so all verifications are repeated. Averna validates boresight, MTF, distortion, stray light, EFL, field curvature and many other functional parameters.