Projects

Selected work across tools, workflows and processes.

These examples demonstrate the range of work I can support, from custom engineering tools and connected workflows to practical process development. They represent a selection rather than a complete portfolio.

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Alignment measurement GUI for lens arrays and silicon array elements
PROJECT 01

Custom Tool: Automated Alignment Analysis

A self-contained executable that measures the alignment between lens arrays and silicon array elements.

  • Challenge: Develop a GUI for measuring post-bond alignment.
  • Approach: Build the core workflow, then use repeated measurements to refine usability and verify the repeatability and accuracy of the results.
  • Outcome: A user-friendly GUI that delivers fast, reliable alignment measurements.
PWS Studio curved-mirror optical simulation workspace
PROJECT 02

Workflow: Curved Mirror Project

An end-to-end PWS Studio workflow connecting optical simulation, device generation, analysis and reporting.

  • Challenge: Take a curved mirror from concept to verified device.
  • Approach: Connect simulation, generation, analysis and reporting.
  • Outcome: A complete, traceable design workflow.
Explore the example workflow
Diffractive lens generator multi-layer GDS layout
PROJECT 03

Custom Tool: Diffractive Lens Generator

Program that generates a multi-layer GDS design for a diffractive lens, to be fabricated by photolithography and reactive ion etching.

  • Challenge: Create a straightforward and usable GUI for generating lens GDS designs for rapid prototyping.
  • Approach: Focus on usability, clear layout and integration with KLayout. Compare the output with a reference design to confirm the generator is viable.
  • Outcome: A verified, repeatable workflow that produces fabrication-ready multi-layer GDS files and reduces design turnaround for rapid prototyping.
PDMS masters, replicated structures and example stamp geometries

AI-generated image illustrating examples of possible PDMS replication structures.

PROJECT 04

PDMS Replication Techniques

A rapid PDMS replication process for prototyping micro-scale optical and packaging structures.

  • Challenge: Develop a fast prototyping process for optical elements such as waveguides, microlenses and packaging structures.
  • Approach: Establish a repeatable moulding workflow, then refine material preparation, curing and demoulding parameters to improve feature quality and reduce turnaround time.
  • Outcome: A practical, repeatable process for producing detailed PDMS prototypes quickly, enabling rapid design evaluation and iteration.
Die bonder process optimisation
PROJECT 05

Die Bonder Process Optimisation

Process development and optimisation for bonding optical components to substrates using Accura-100 and FC-300 die bonders.

  • Challenge: Achieve reliable placement and bonding of optical components while maintaining alignment and protecting sensitive surfaces.
  • Approach: Develop and refine Accura-100 and FC-300 bonding workflows, adjusting handling, alignment and process parameters for different component and substrate combinations.
  • Outcome: A controlled, repeatable bonding process that improves placement consistency and supports efficient optical assembly development.

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Have a project that requires a tailored technical approach?

Get in touch to discuss optical modelling, device development, engineering automation or prototype support.

Your enquiry will be sent directly. You can also email rowan@photonicsworkflowsolutions.co.uk.