We have a deep expertise in opto-mechanical design. That includes complete mechanical and electrical systems design, optics packaging, sealing and focus mechanisms. Our experience ranges from consumer products (AR/VR, and automotive) to industrial, and defense.
- New product design from sketch to first article
- Virtual simulation
- Rapid prototyping
- Individualized machining and fabrication
Here are some examples of optomechanical design projects we have worked on over the years.
Handheld Optics
Binoculars and Monocular
We developed thermal binoculars and a handheld monocular for a client in the defense thermal imaging space. They were designed for long range use in any condition day or night, by search and rescue, law enforcement, defense or military operations.
We started with a product requirement document*, developed a first article working prototype, followed by revisions and a ten-unit design for field trials. 
Both projects were a success and we have continued to work with the client. The monocular was made available on Amazon.
CMOS Night Observation Device
We were brought in to do the complete mechanical design, including optics packaging and UX design on a CMOS night observation device. The client, a vertically integrated manufacturer of precision optical product solutions based in New York, won the Prism Award for our work.
The device needed to be usable in both a handheld and weapons mountable application, have the ability to focus at night, and the housing needed to be water tight. We did the complete mechanical design, optics packaging and UX Design.
Modular laser and dazzler attachments for weapons
We were asked to re-design the VFG (vertical fore grip) of a weapon, adding a modular laser and dazzler attachment and ruggedizing it for Law Enforcement. We had to navigate tight design constraints and the final product resulted in patents being issued.
Thermal Smartphone Camera
We developed the SEEK Compact camera in a fixed-focus format with SKUs for compatibility with Apple and Android phones. That meant taking their low-cost, long-wave infrared imaging sensor and integrating the sensor electronics, molded lens, custom shutter for non-uniformity correction, and USB attachment, and packaging it all in a rugged enclosure. See the full case study at Smartphone Accessory Thermal Camera.
Vehicle Mounted Optics
Helicopter Under belly POD
We were engaged by a large natural gas company to develop an underbelly POD for mounting on a helicopter that would carry optical equipment. The POD was to house six high-speed video cameras, hardware, GPS, racks, and cabling to perform arial surveys of gas and electric utility lines. We had to include an anti-condensation system, so the cameras would not get blurry and qualify for a full Certification for rotorcraft use. We handled full ME and prototype build on the project.
Vehicle Bumper Mounted Camera Housing
A big company in the thermal imaging space asked us to redesign a bumper mounted housing for thermal cameras for use by the military for troop protection. The device required Thermal Compensation rings to maintain focus over desert temperature swings and an anti-condensation system.
Max-Viz Thermal Imaging for Pilots
Max-Viz, an aerospace company dedicated to developing Enhanced Vision Systems for the aviation industry, turned to Sherpa Design for their first product, the EVS 100.
The goal was to extend a pilot’s forward vision by at least eight times what the naked eye could see in challenging weather conditions or during nighttime flights. Max-Viz had already acquired a military-grade thermal imaging camera, licensed an uncooled focal plane array, and developed a patented system to fuse video images. They needed our expertise in industrial design and mechanical engineering, integrating these components into a sleek, aerodynamic housing that could be mounted on various aircraft. Read the full case study at Max-Viz Thermal Camera.
OGI: Optical Gas Inspection Camera
We worked with a big company in the oil and gas inspection industry that wanted to develop a new camera for monitoring and GPS tagging industrial gas leaks for new EPA monitoring requirements.
VR/AR
We are working with some of the biggest companies in the world on several virtual reality projects. While we cannot share any details of these, our engineers have deep experience in this field.
Looking for innovative product design in the Opti-Mechanical space?
