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A small-form-factor (SFF) blue-light optical pickup head (OPH) with holographic optical element (HOE) has been fabricated and assembled. The assembly and alignment of various components in the pickup head were facilitated by using a flip chip bonder. Experimental results indicated that the focusing error signal (FES) of the assembled OPH with the wavelength of 405 nm could be successfully detected. The linear range of the FES was about than 4 μm. The gauge repeatability and reproducibility (GR&R) of the assembly process was tested and found to be acceptable.