Developing an optical system from scratch involves many tasks and activities. From the design step to the delivery of the product, anything can lead to (mostly bad) surprises. Complex specifications, very challenging requirements, difficult technical choices, frightening tests or after-shipping non-compliance... the path to a good product is paved with many traps. This paper will present some of these issues, along with the solutions found to mitigate them, that occurred on the Spectral Separation Assembly, a sub-system of the Flexible Combined Imager, the main imaging instrument of the Meteosat Third Generation mission.
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