Vermont Photonics
Case Study: Lawrence Berkeley National Laboratory Advanced Light Source
THE CHALLENGE
The Advanced Light Source at Lawrence Berkeley National Laboratory operates at the forefront of x-ray optics performance. To characterize these optics, measurement demands exceed conventional capabilities by orders of magnitude. The facility faced critical metrology challenges that threatened both research timelines and beamline performance outcomes.
Technical Requirements Beyond Standard Capabilities
The team had a need to characterize meter-long x-ray mirrors with single-digit nanometer height accuracy, a specification that no commercially available off-the-shelf metrology solution can address. While standard optical specifications consider lambda over 20 as excellent quality, x-ray applications require precision where such tolerances are inadequate.
"For x-rays, lambda over 20 is laughable. There are no tools on the planet that can achieve what we need. We're doing what we can to understand the information we can gather using the tools available."
— Ian Lacey, Scientific Engineering Associate
Critical Mission Requirements
The facility's upgrade program required characterizing more than 50 high-precision optics within a single year, unprecedented throughput for measurements at this accuracy level. Each optic represents investments exceeding $100,000 and manufacturing lead times of one to two years, making measurement accuracy essential for:
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Predicting beamline performance before x-ray source activation
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Identifying which optical components require tuning or adjustment
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Selecting optimal optics from limited production batches
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Providing feedback to manufacturers on perturbations and surface quality
Measurement accuracy directly impacts the facility's ability to support cutting-edge research across materials science, chemistry, and physics applications that depend on preserving coherent x-ray beam characteristics.
THE SOLUTION
Vermont Photonics provided comprehensive metrology solutions centered on electronic autocollimators from Möller-Wedel Optical GmbH (MWO), supported by technical expertise and customized integration services.
Precision Instrumentation Portfolio
The Advanced Light Source deployed multiple autocollimators from the ELCOMAT line for their metrology system:
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ELCOMAT HR: The highest accuracy ELCOMAT model with measurement accuracy of ±0.01 arcsecond, deployed in a monitoring / reference role as part of the lab's multi-instrument measurement system
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ELCOMAT 5000/10: Based on the flagship ELCOMAT 5000, this special version is used to directly measure the surface of the optic with an aperture of just a few millimeters
With a total of four autocollimators in one of their systems, this multi-instrument approach enables anti-correlation measurements to reduce systematic errors, essential for achieving the accuracy levels required for x-ray optics characterization.
Technical Partnership and Customization
Vermont Photonics' value extended beyond equipment supply to encompass:
Calibration Coordination
Managing the complex logistics of international calibration services with MWO in Germany, including pre-shipment calibration and subsequent recalibration cycles to maintain traceability to international standards.
Sourcing Extended Cables
Providing extended cables and coordinating accessory deliveries to accommodate the unique geometries of synchrotron beamline measurement environments.
Instrument Upgrades
Facilitating the upgrade of legacy ELCOMAT 3000/8 autocollimators to 3000/10 specifications, ensuring measurement consistency across the instrument suite and maintaining long-term investment value.
LabVIEW (and EPICS) Integration
Supplying drivers and integration support for simultaneous data acquisition from multiple instruments, that simultaniously run multiple motion control schemes, enabling comprehensive measurement workflows.
THE RESULTS
Unprecedented Throughput Achievement
The implementation of Vermont Photonics' metrology solutions enabled the Advanced Light Source to reduce measurement time for comprehensive optic characterization from 28 calendar days to approximately 50 hours of largely automated data acquisition. This 10x improvement in throughput was essential for completing the facility's largest characterization program, successfully measuring over 50 optics during one phase of the upgrade period.
Enhanced Measurement Capability
The exceptional repeatability of ELCOMAT autocollimators enabled advanced anti-correlation techniques that compensate for systematic errors. By deploying autocollimators on multiple measurement tools in different orientations, the team achieved:
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Noise floor performance of approximately 30 nanoradians RMS—five times less than the curvature of Earth over a meter distance
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Detection, characterization, and suppression of periodic perturbations with 12-microradian periodicity
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Differentiation between actual surface features and measurement system artifacts
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Selection capability for identifying the highest-quality optics from production batches
“The repeatability has been incredibly helpful. With repeatability, we can anti-correlate results and really help get down and down and down… We're better by a factor of 5 than the curvature of the Earth, and we're trying to push that lower still.”
— Ian Lacey
Operational Confidence and Quality Assurance
The implementation of metrology solutions from Vermont Photonics addressed a fundamental industry challenge: manufacturers could not improve x-ray optic quality without the measurement capability to verify their work. By providing autocollimators with the necessary accuracy and calibration traceability, Vermont Photonics enabled the Advanced Light Source to deliver credible feedback that manufacturers could trust and act upon.
This measurement authority proved essential for closing the feedback loop between metrology and manufacturing, contributing to observable improvements in recent production batches with reduced periodic perturbations.
Research Advancement
Access to accurate metrology data enabled the team to develop novel measurement techniques, including strategic use of non-standard apertures for challenging geometries such as toroidal mirrors with extreme curvature ratios. This research contributes to the broader x-ray optics community's understanding of measurement limitations and optimization strategies for next-generation synchrotron applications.
KEY SUCCESS FACTORS
Long-Term Partnership Approach
"The ability to continue to offer support, even for one of our older autocollimators to get that upgraded, and working with the calibrations has been incredibly helpful…I've really appreciated the support from Vermont Photonics. ”
— Ian Lacey
The partnership's success stemmed from Vermont Photonics' recognition that the Advanced Light Source represents a non-standard customer with demands that exceed typical applications. Rather than constraining solutions to standard specifications, Vermont Photonics worked collaboratively to understand unique requirements and facilitate access to advanced capabilities.
Technical Expertise and Communication
Vermont Photonics demonstrated an understanding of both the instrumentation and the application requirements. The company's technical team provided accurate logistics communication, avoiding over-promising while delivering comprehensive support for complex challenges including:
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Environmental troubleshooting for oscillation anomalies in ELCOMAT HR units
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Accurate delivery timing communication, enabling effective facility planning
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Technical consultation on measurement strategies and equipment configuration
Flexibility and Problem-Solving
Vermont Photonics' willingness to address seemingly minor but critical details—such as sourcing extended cables for complex facilities—demonstrated commitment to complete solution delivery rather than simply equipment sales.
The company's coordination with MWO on behalf of the customer, illustrated the value of their four-decade partnership.
LOOKING FORWARD
As x-ray sources worldwide continue to advance toward next generation light sources, measurement demands will intensify. The Advanced Light Source anticipates continued collaboration with Vermont Photonics to address emerging challenges including:
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Exploration of additional configuration parameters and illumination sources
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Integration of advanced measurement strategies for next-generation coherent x-ray sources
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Continued instrument calibration and upgrade support to maintain measurement traceability
CUSTOMER TESTIMONIAL
I think a main reason for Vermont Photonics is the access to Möller-Wedel, and they seem to make quality equipment that we can understand. But I think we've appreciated the support, working with calibrations, and even just the little idiosyncrasies of getting the details right. You have a great tool, but when we need a different cable, or extra adapter widgets that we can customize — these details help me make the whole thing work. The partnership is vital, and the day-to-day has been really helpful.
— Ian Lacey
Scientific Engineering Associate
Photon Science Development Group
Advanced Light Source, Lawrence Berkeley National Laboratory
ABOUT VERMONT PHOTONICS
Vermont Photonics has served as the exclusive North American distributor of Möller-Wedel Optical GmbH equipment for over 40 years, and of Eitzenberger GmbH air bearing systems since 2024.
The company’s mission is to advance precision engineering through world-class metrology expertise and exceptional customer service.
Vermont Photonics' team of physicists and engineers provides technical expertise in optical metrology and precision motion systems in critical applications across aerospace, defense, research, and precision manufacturing.
For more information about Vermont Photonics' metrology solutions and technical support capabilities,
contact our expert team at 802-275-5210 or
visit www.vermontphotonics.com