Design for manufacture is a phrase commonly used to describe how manufacturing considerations are incorporated into the optical design process. OpticStudio offers several capabilities that support design for manufacture, and the Cost Estimator takes the concept to new heights by allowing users to get real-time cost estimates direct from manufacturers. This tool uses an XML file, generated from data in the ISO 10110 drawing to ensure a seamless data exchange.

Authored By Zachary Derocher

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Introduction

OpticStudio offers several capabilities that support design for manufacture, and the Cost Estimator takes the concept to new heights. The tool allows you to send lens data to manufacturers and get real-time cost estimates. The designer can then see the cost impact of lens shape, size, material, coatings, quality and quantity. This capability is unprecedented in the optical design software industry.

This article will provide a tutorial on how to use the Cost Estimator tool. 

Registering with manufacturers

Prior to using the Cost Estimator, users must register with the supported manufacturer. Below you will find instructions on registering with supported manufacturers.

Optimax

For a complete description of usage of the Optimax estimator, please refer to the documentation available for download in the Article Attachments section above. 

Go to the website for the Optimax Estimator here and click the link to register. 

Once you have registered with the desired manufacturer, open OpticStudio and click Manage Providers in the Cost Estimator section of the System Explorer. Click on the desired provider and enter your username and password provided by the vendor. After closing the dialog, the information will be saved and the estimator will be ready to use.

Password information can be saved in an encrypted format using the Export Provider Data button in the System Explorer. Later, when the password needs to be reloaded, it can be imported using the Import Provider Data button.

Using the Cost Estimator

The Cost Estimator can be found in two locations in OpticStudio. It can be launched from the Tolerance ribbon or from the dedicated tab in the ISO 10110 drawing:

The tool requires several pieces of information provided in the ISO 10110 drawing in order to provide cost estimates. The lens shape, size, material, coatings, and quality (tolerances) are all needed. Tolerances should be pulled in from the tolerance data editor by clicking the “Reset from TDE” button in the tolerance data editor (TDE). Please note that not all settings in the ISO inputs are considered for cost estimation; the inputs utilized in cost estimation vary depending on the providor used. See below for providor-specific information. Once all this information is in the ISO 10110 drawing, the user can proceed to define the settings for the estimator.

Optimax Cost Estimator supported parameters

When using Optimax as the Cost Estimator, the following fields (highlighted in the images below) are considered:

The definitions of the Diameter inputs in the first image above are as follows: 

Effective Diameter: This is the clear aperture for the surface (area over which form and cosmetic tolerances must be met).

Diameter: This is the effective diameter plus the chip zone (over which the surface form continues). For concave surfaces, it is also called the opening.

Diameter (flat): This is the overall finished part diameter. For concave surfaces, it is the diameter of the opening plus the flat area (sag face). For convex surfaces, the diameter and diameter (flat) are usually the same value.

Generating the Cost Estimate

When opening the Cost Estimator from the ISO 10110 drawing, the currently configured lens will be used for cost estimates. The user defines the manufacturer and quantities they would like estimates for. Multiple quantities can be quoted simultaneously by using commas to separate them.

Once the settings are defined properly, click OK and the estimator will obtain estimates from the selected providers. If the unit costs are returned as zero, check the messages for errors in the lens data sent.

The Cost Estimator launched from the Tolerance ribbon offers similar functionality with a few more options. This tool loads lens data from an XML file (generated by the ISO 10110 drawing) or directly from a ZMX file. Alternately the user can create a new part directly within the tool by entering the lens data manually. Multiple lenses can be loaded simultaneously. Selecting a specific part from the list at the top of the tool will list its surface and material data in the center of the dialog. Cost estimates are provided at the bottom of the dialog after pressing Refresh Estimates.

Vendor limitations and information

Cost estimate providors have some limitations in the values that can be used, in either the lens prescription, cost estimator settings, or tolerances. Some of the limitations and other pertinent informations for currently supported providors are provided below. 

Optimax

Please refer to the Optimax Cost Estimator documentation, provided as an article attachment, for a full set of information. This is a useful tool for understanding how lens properties affect the estimates returned. 

The Estimator is designed around prototype optics that Optimax can deliver in 1 week, and is thus limited in scope to a set of boundary conditions. For example, the glasses used in the lens prescription must be from OpticStudio's default OPTIMAX glass catalog. Another example is that there are minimum values allowed on tolerance inputs (precision limitations). For a complete set of cost estimate boundary conditions, please refer to the Optimax Cost Estimator Documentation. Please note that the actual full scope of manufacturing capabilities at Optimax are much broader. 

When using Optimax as the provider, error messages will be returned if the data submitted violates any of the above limitations. Those error codes are listed below.

KA-01516