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 positioning tolerances, active alignment dynamically adjusts the lens position while monitoring image feedback in real time.

This technique ensures sub-micron accuracy for critical parameters like focus, center, tilt, and rotation. Active alignment is essential in mass production of advanced imaging systems—such as those used in smartphones or other connected devices, automotive ADAS, medical devices, and industrial vision—where performance, consistency, and throughput are key.

The assembly of camera modules requires precision and perfection

Each step needs to be performed meticulously to avoid any flaw or defect. Averna ensures the highest quality alignment for all types of cameras used in hundreds of applications from cellphones to autonomous vehicles and everything in between. The same technology can be applied in the assembly of any application based on matrix LED or laser technology including multi-beam headlights.

Our active alignment machine produces the highest quality and flexibility with minimal retooling required between product types. Thanks to our smart systems testing, we ensure crystal-clear images through precise lens-to-sensor alignment using NEN 12233 or Averna-specific focus and alignment algorithms supporting large fields of view and boresight optimization.

Our expertise includes semi and fully automated test equipment as well as small and bench-top prototype solutions allowing our customers to optimize results before designs are frozen. This is how we ensure every solution produces fast results at a high yield.

Why Choose Averna for your Camera Module Testing

Poor alignment during the camera module assembly process can lead to blurry images, inaccurate depth perception, and major quality issues—especially in high-performance applications like ADAS AR/VR/MR, or cell phone applications. Manual or passive alignment methods often fall short when it comes to precision, repeatability, and production speed.

That’s where Averna makes the difference.

We help manufacturers tackle the most common challenges in active alignment:

Sub-micron accuracy requirements with low process variability

High throughput in mass production without compromising image quality

Alignment stability under thermal and mechanical stress

Complex product mixes requiring fast changeover and minimal downtime

With over two decades of expertise in vision systems and automation, Averna delivers robust, production-ready platforms tailored to your product and yield targets. Our integrated approach combines optical metrology, image processing, robotics, and proprietary alignment algorithms to ensure consistent, top-tier performance—whether you’re prototyping or scaling up globally.

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 critical role in delivering high-quality images, especially in applications requiring precision and reliability.

Preparation

All optical and electronic components undergo rigorous vision inspection system checks to ensure they are defect-free before assembly. Every millimeter of every surface must be cleaned, treated, tested and verified before the pieces are assembled. The equipment ensures the appropriate lens quality is present to perform a chip test detecting hot, dark and dead pixels and to perform the required current, pixel response, uniformity tests and many more.

Dispensing

Dispensation is executed accurately and deliberately to avoid creating deformities caused by glue beading. Multiple dispensing techniques are supported including jetting and volumetric dispensing. Parameters are precisely controlled to compensate for varying glue conditions such as viscosity and repair functionalities are available should incomplete glue beading occur. Machine vision technology is used to measure the exact dispensing position and analyses the result at an early stage.

Alignment

Within a clean equipment environment, alignment is performed using a fully automated multi-axis motion system. Using a variety of targets and/or projections while verifying touch-points, the components are assembled together. Testing and substantiation is performed dynamically throughout the process producing accuracy to the micrometer in accordance to NEN12233 or by Averna specific focus and alignment algorithms.

UV-Curing

Still within the alignment environment, UV-curing of the glue is performed. This is a multi-step and real-time process as curing can shift the components from their original setting. Curing must be factored into the original measurements and tests, accounting for the continuous verification of test points throughout the assembly process. Multiple episodes of thermal curing are necessary to offer a solid structure.

Validation

The assembled product is then re-validated before it is finalized as each step may cause its own potential defect. The smallest fault within any component is quickly augmented and detrimental to the system as a whole. All verifications and tests are re-performed, regardless if the system is simple or complex, guaranteeing flawlessness and total quality. Averna’s solutions support inspection of boresight, MTF, distortion, stray light, EFL, field curvature and many more functional and end-of-line validations.

Cover of the Active Alignment Assembly and Test Platform Brochure

Find the Right Solution for Perfect 2D and 3D Component Alignment and Positioning

Find a semi or fully automated active alignment solution to quickly assemble camera & LiDAR modules, MEMS devices, die based sensors, LED and laser-based headlights and other high-end products with supreme accuracy. Download this brochure to discover which automated quality platform best fits your manufacturing requirements.

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