Optical Bonding Design Service Consultation

FPD.DEV provides optical bonding design and process development services for LCD display manufacturers, system integrators, and companies developing ruggedized, high-performance display products.

Services include optical bonding design support, 3D modeling, tooling concepts, fixture development, material and process evaluation, design-for-bonding review, and guidance on whether to outsource optical bonding or develop an internal bonding capability. FPD.DEV can also help identify and qualify suppliers capable of meeting your product requirements, production volume, environmental demands, optical performance targets, reliability expectations, and business constraints.

Many companies strive to meet demanding optical, environmental, and manufacturing requirements but struggle to connect design intent, material behavior, process control, supplier capability, and production reality. FPD.DEV helps close that gap by translating product requirements into practical bonding methods, tooling strategies, supplier selection criteria, inspection plans, and scalable manufacturing processes.

The work is led by Diggy Breiling, whose experience with LCD display repair began in approximately 1992, when he helped launch and operate a startup notebook computer depot repair facility. By 1994, he was developing optical bonding methods to make LCDs suitable for replacing CRTs in aerospace display applications, where optical performance, ruggedness, reliability, and environmental durability were critical.  In 1999 Diggy filed his first patent for novel optical bonding of avionics displays that achieved 0.7% total reflection when previously 1.5% was the lowest achievable (US Patent 6181394) and went on to file many more.  

Diggy has developed patented optical bonding technology associated with VIA Optronics and has directly transferred optical bonding technologies to companies including Planar Systems in Oregon, Litemax in Taiwan, PNS in South Korea, and IDS Display in Irvine, California. He has also worked with and trained engineers across many optical bonding operations in the United States.

FPD.DEV’s experience extends beyond displays. Similar bonding methods have been applied to solar concentrator applications exposed to extreme thermal swings, from arctic cold temperatures to concentrated full sunlight focused onto bonded solar panel assemblies. These applications have demonstrated survival from approximately -65°C to over 200°C, showing the importance of material selection, process control, stress management, and environmental validation.

FPD.DEV can support companies seeking to build their own optical bonding capability, from low-volume manual bonding cells to automated processes that reduce hands-on labor from hours per display to minutes. In mature automated environments, the largest remaining manual labor content is often receiving, unboxing, inspection, cleaning, final inspection, and repackaging rather than the bonding process itself.

Diggy’s optical bonding experience is supported by a broader background in quality systems, manufacturing process control, operations management, and supply chain discipline, including ASQ certifications in CMDA, CMQ/OE, and CSSBB, and APICS certifications in CPIM and CSCP. This allows FPD.DEV to approach optical bonding not only as a display technology challenge, but as a controlled manufacturing process with defined risks, repeatable methods, supplier controls, inspection criteria, and scalable production logic.