Consistently high performance LED application with ESCATEC back-end cooling system

ESCATEC, the Swiss electronic design and manufacturing service provider, helped transform the illumination quality of a recently released ophthalmic microscope. Its  Micro Opto Electronic Mechanical Systems (MOEMS) facility created the new technology for a customer, which now guarantees a reliable LED light source, thereby increasing the success rate  of cataract surgery.

Conventional LED red reflex illumination technology offers surgeons optimal views of the eye’s structure and texture. However, the quality of red reflex illumination provided by conventional light technology decreases during the most crucial phases of ophthalmic surgery. For this reason, a leading microscope manufacturer contracted the MOEMS facility at ESCATEC in Heerbrugg, Switzerland, to design and produce a new red reflex LED light source solution. ESCATEC quickly developed a new high efficiency LED module with four individual beam paths to overcome the drawbacks of the conventional illumination technology.  The new module now provides consistent, high quality and detailed ophthalmic views throughout the entire surgical procedure.

LED generated heat challenges solved through thermal management
Using a high resolution thermal simulation tool primarily developed by the University of Vienna, thermal simulation models were quickly generated and optimised from complex structures. The quality and consistency of the light source was optimised and a back-end cooling system was designed and manufactured to prevent overheating. The new light module’s micro-assembly, thermal management assembly, packaging, and testing were all completed at the cutting-edge MOEMS facility at ESCATEC in Switzerland.

“For almost every LED application heat is the major enemy. Thermal management is a challenge for every LED and LASER device designer and this is where ESCATEC was able to develop a specific solution,” says Wolfgang Plank, head of the MOEMS facility, “our customers wanted the higher performance of LED lights, with lower service costs, as an alternative to the previous Xenon technology. Our extensive experience with LEDs enabled us to quickly deliver the right solution.”



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