We present a tolerance-sensitivity–driven, manufacturability-aware strategy integrating optical design and alignment for optomechatronic imaging, validated in a fluorescence laparoscope. A chromatically corrected, structurally optimized design achieves near co-focal imaging across 450–1000 nm and anchors tolerance analysis and alignment planning. Simulations show strong axial-misalignment sensitivity, with decentering tolerances as tight as Formula: see text mm, near fabrication limits. We implement a hybrid alignment approach combining active compensation with passive constraints and validate it on batch prototypes. Five units were fabricated, aligned, and evaluated per YY 0068.1–2008; all met specification (100% yield), with central angular resolution Formula: see text cycles/deg in the visible (spec Formula: see text) and Formula: see text cycles/deg near 1000 nm (spec Formula: see text), a Formula: see text field of view, and distortion Formula: see text The co-optimization preserves broadband image quality and high optical resolving power without tightening manufacturing tolerances, enabling scalable production and offering a transferable methodology for related endoscopic systems.
Zhou et al. (Thu,) studied this question.