Tolerance-Sensitivity-driven alignment and design strategy for wide-spectrum high-resolution fluorescence laparoscopes: from optical design to batch manufacturing

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.