en.Wedoany.com Reported - A research team at Heriot-Watt University has developed a laser-based process that directly constructs optical alignment structures inside glass components, eliminating the manual calibration step that accounts for more than half the cost in traditional photonics manufacturing, achieving assembly precision with sub-micron tolerances.
This technology is led by Dr Calum Ross from the university's School of Engineering and Physical Sciences and is being commercialized through the spin-out company FreeForm Photonics. Traditional photonic component assembly relies on cumbersome manual adjustments or expensive active alignment systems, with each adjustment adding time, cost, and risk of error. The new process integrates passive alignment features directly into the glass components themselves, embedding precision into the parts from the outset of manufacturing.
The technology can be applied to quantum computing systems, medical diagnostic devices, and optical communication infrastructure—fields that depend on photonic components currently assembled primarily by hand. Potential applications also include fiber optic sensing in extreme industrial environments.
FreeForm Photonics has secured funding through Scottish Enterprise's High-Growth Spin-Out Programme to create a scalable company and prepare for seed round investment. Derek Shaw, Director of Entrepreneurship and Investment at Scottish Enterprise, stated that the technology has the potential to transform photonics manufacturing and drive advancements in quantum, medical, and communications sectors.
The global photonics component market was valued at nearly $1 billion in 2024 and is expected to grow significantly. According to the team, over 100 industry leaders and potential customers have evaluated the technology, with strong interest expressed for adoption at medium-volume production scales. Trial samples have been provided to customers in the aerospace, telecommunications, and medical sectors.
Professor Gillian Murray, Vice-Principal for Enterprise and Business at Heriot-Watt University, stated that the university helps transform laboratory research into globally competitive high-growth enterprises through entrepreneurship programs and business support.
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