Patent ID: 7304814

Claim:
A method for aligning and coupling an optical component to a substrate with a precision of at least 12.5 microns in position and 0.075 degrees in angular orientation, comprising: (a) machining an optical component from a material selected from the group consisting of at least one of aluminum, aluminum alloys, stainless steel, nickel, copper and beryllium; (b) affixing the optical component to a mount having a flat bottom surface that defines a first plane, wherein a cylindrical rod extends away from the flat bottom surface of the mount at an angle perpendicular to the first plane, and wherein at least first and second screws are disposed in first and second cylindrical openings that extend through the bottom surface of the mount, the first and second cylindrical openings in the mount being aligned perpendicular to the first plane and having an inner diameter that matches an outer diameter of the first and second screws; (c) providing a substrate having a flat upper surface that defines a second plane, wherein a first cylindrical opening extends from the upper surface of the substrate into the substrate at an angle perpendicular to the second plane, and wherein at least second and third threaded openings extend from the upper surface of the substrate into the substrate at an angle perpendicular to the second plane; (d) positioning the mount with respect to the substrate by simultaneously aligning the metal rod with the first opening in the substrate, the first opening in the mount with the second threaded opening in the substrate, and the second opening in the mount with the third threaded opening in the substrate; (e) while the mount and the substrate are aligned, inserting the cylindrical rod into the first cylindrical opening in the substrate until the bottom surface of the mount contacts the upper surface of the substrate, wherein, following said inserting, friction between the cylindrical rod and the first opening in the substrate inhibits rotation of the mount about an axis perpendicular to the first and second planes and tightness between the first opening in the substrate and the cylindrical rod restricts lateral movement of the mount with respect to the substrate; and (f) after step (e), rotating the first and second screws into the second and third threaded openings respectively in the substrate, whereby the mount is coupled to the substrate with said precision.