Optical & Hardware Design Intern

About the Role

Optical & Hardware Design Intern at PulseForge Labs.

Key Responsibilities

• Model the imaging path in Zemax, simulating the full optical train (schematic eye, ophthalmoscopy lens, relay optics, smartphone camera) in sequential mode.
• Optimize image quality by tuning field of view, resolution (MTF), distortion, and working distance, and checking performance across validated handsets.
• Design illumination, simulating the LED source, annular illumination, and polarizers in non-sequential mode, and suppressing corneal and lens reflections.
• Check light safety by calculating retinal exposure and ensuring it stays within ISO 15004-2 and IEC 62471 limits.
• Perform tolerance analysis for manufacturing and translate results into lens and assembly specifications for vendors.
• Design hardware in CAD, including the lens barrel, phone clamp, and alignment features.
• Prototype and test using 3D-printed prototypes with off-the-shelf lenses, testing on a model eye, and comparing results with simulations.
• Document design choices, results, lens prescriptions, Zemax files, test results, and bill of materials for regulatory technical files.

Requirements & Tech Stack

• Working access to Zemax OpticStudio (personal or institutional license) for the entire internship.
• Strong geometric optics knowledge, including aberrations, stops and pupils, paraxial design, and MTF.
• Hands-on sequential design experience in Zemax (lens data editor, merit functions, optimization, tolerancing).
• Working knowledge of a CAD tool such as Fusion 360 or SolidWorks.
• Clear written documentation of design choices and results.

Qualifications

• Pursuing or completed a B.Tech, M.Tech, or M.Sc in optics, photonics, physics, electrical, or mechanical engineering.

Good to Have

• Non-sequential and illumination design, including stray-light analysis.
• Knowledge of ophthalmic optics, schematic eye models (e.g., Liou-Brennan or Navarro), or fundus imaging.
• Experience with smartphone camera modules or compact imaging systems.
• 3D printing and hands-on optical bench work.
• Python or MATLAB for analysis, or Zemax automation through ZOS-API.
• Familiarity with medical device standards such as ISO 13485 and ISO 15004-2.