Custom Camera Modules

Depending on the requirements, we can provide design and manufacturing services for a complete sensor module. We strive to find the best solution for your needs, from designing the schematic, creating the PCB layout, and sourcing all components to building according to your PCB design and parts consignment.
At Sunex, we have the in-house expertise and capabilities for lens and sensor board design, high-volume manufacturing, automated active alignment, and testing to support the most demanding vision applications.
For additional services, we can bring in partners from our Technology and Service Network that allow us to process bare die and packaged sensors, including cabling options, e.g., for medical applications, and hand over the complete tested sensor module to the following entity in the value chain to integrate the full camera.

Always designed with mass production in mind.

Often it is not the challenge to create a design “that works” but to find a solution that can scale to mass production, meeting price targets, optical performance, mechanical constraints, and quality requirements. Sunex has over two decades of design and manufacturing experience, and all our lenses and modules are designed for high-volume manufacturability.

“Technical and commercial requirements and mutual understanding and alignment of milestones, deliverables, and timelines are all imperative for taking initial prototypes successfully through to mass production, and we recommend contacting us as early as possible in the product development cycle.“

Ben Roberts, Sunex VP of Sales and Marketing

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Key Technologies

System-level Athermalization
The shift of a lens’s focal point over a wide temperature range is a physical phenomenon based on the material-specific expansion and contraction with temperature. A decrease in image quality could be the outcome if the focal point of the lens relative to the sensor’s image plane shifts too much. A fully athermalized system requires selecting appropriate optical and mechanical materials, employing the right design strategy, and close collaboration with the customer to optimize thermal performance at the system level.

Active Alignment
We recommend that our customers consider an active alignment process to achieve the highest system performance when pairing a high-quality lens with a high-resolution sensor. Our active alignment offering can grow with the ramp of the program and enables the use of an alignment process from the beginning. Applying a fully automated 6-axis active alignment in mass production increases yield, shortens cycle times, improves system performance, and lowers part-to-part variance.

Fast Prototyping
In specific cases, prototyping is used as the first stepping stone toward mass production. Besides the lens performance, exploring various mechanical design solutions is often part of these early efforts. Staying within the required dimensions while accommodating additional working channels and features is crucial for a successful product.
Sunex can produce prototypes with short lead times to verify the design before transitioning further on the path to mass production using state-of-the-art fabrication processes for glass and plastic optical elements and all mechanical components.

Reliability and Environmental Testing
Often, it is not the challenge to create a design “that works” but to find a solution that can scale to mass production (DFM), meets required price targets (DTC), and delivers on performance and quality (DFR). Our deep design and manufacturing experience comes from servicing some of the most demanding markets and applications, and combined with consistent quality and global on-time delivery, Sunex is the preferred partner for many.

Supporting Services

Partner Network
We work with our customers and partner network to find the best balance between cost and performance to meet the often unique application requirements. Sunex offers a wide range of services, including designing and manufacturing the lens and the optomechanical components, the PCBA, and the right cabling solution. Sunex has the expertise and capabilities for high-volume manufacturing in state-of-the-art
cleanroom facilities, automated 6-axis active alignment, and the test and quality control processes required to support the most demanding medical imaging applications.