Conducted in an ultra-clean room (typically Class 10,000 or even Class 1,000), this process involves the precise integration of critical optical components—including the light source (LED or laser), illumination unit, dichroic mirrors/color combining prisms, DMD chip (for DLP technology) or LCD panels (for 3LCD technology), and the projection lens—onto the optical engine substrate. This is achieved using robotic arms or specialized equipment with micrometer-level precision.

This is the most critical step. Simply tightening screws for fixation is insufficient. The system powers on the chip to display specific test patterns, while a high-precision CCD camera positioned behind the lens captures the projected image in real time. Based on image quality metrics (such as sharpness, centering, and color uniformity), a computer system dynamically fine-tunes the six degrees of freedom (X, Y, Z, pitch, yaw, roll) position of the optical elements (especially the DMD chip and lens) until the optical performance is optimized at the "sweet spot". Only then are the components permanently secured.

Once assembled, the optical engine is immediately sealed to prevent ingress of external contaminants. Even a microscopic dust particle settling on the DMD chip or a lens element will be magnified into a permanent, highly visible dark spot on the projected image, creating an irreparable defect.

Prior to manufacturing, CFD (Computational Fluid Dynamics) software is used to simulate and optimize the entire system's airflow path. This process refines the heat sink geometry, fan placement, and duct design to eliminate any potential thermal hotspots.

High-performance thermal paste or pads are meticulously dispensed or applied between critical heat-generating components (e.g., the light source, main processor) and their heat sinks. The thickness, area, and uniformity of application are strictly controlled, as deviations can significantly impact heat transfer efficiency.

Low-noise, high-static-pressure fans are selected and precisely mounted within the engineered airflow channel to ensure optimal cooling performance and efficient heat dissipation.

Fully assembled units are transferred to a darkroom and connected to a fully automated test station. This station is equipped with an integrating sphere (for measuring luminance and color temperature), a colorimeter or spectrophotometer (for measuring color gamut and accuracy), and an imaging colorimeter.

The system then writes a unique set of calibration parameters (e.g., Gamma lookup tables, color matrix coefficients, white balance gains) into the projector's non-volatile memory. This process essentially creates a distinct "personality" profile for each individual unit, ensuring consistent display performance across all production units.