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Optical Manufacturing Processes

Optics Manufacturing

I have worked both hands-on and in a process engineering capacity with optics ranging from 1.5 mm to 2.56 m in diameter; thickness down to 90 mm; with materials of all types including a range of glass, metals, gain crystals, nonlinear and birefringent crystals; with hardness ranging from NaCl to Al2O3; in configurations including flat, radius, prism, cylinder, aspheric, multi-surface, lightweight, water-cooled, gas-cooled, and assemblies. I've also developed tooling, fixturing, handling and test methods for unique projects. I developed and taught a six-month apprentice program for a major laser manufacturer that brought new-hires to the level of five- to ten-year veteran opticians; and have presented training programs for several major precision optics companies' technicians.

Manufacturing Methods

• Unit quantity to production line

• Conventional fabrication

• Planetary polishing

• Diamond turning

• Tooling and fixturing

• Flat, radius, cylinder, prism and asphere

• Contacting, cementing and stacking

• Precision dicing

• Cleaning

• Little-known tips and tricks

  You will get efficient and thoughtful service from optec.

• Double-side lapping and polishing

Process Optimization

• Risk mitigation

• Tooling and technique

• Sequence and method

• Integrating test methods with tooling

• Multiplying IPQA effectiveness

• Preserving the value added

At its very core, the Fraunhofer Group for Light & Surfaces develops optical systems for a variety of applications in lighting engineering, material analysis as well as in laser and measurement technology. In addition to designing and producing optical components, the group’s institutes can provide the entire process chain for the production of optical systems. They can develop and manufacture customer-specific optical systems, from the prototype to the finished product. In extensive development and test phases, they examine and evaluate these systems up to their serial integration. Furthermore, the institutes in the group have corresponding test benches and stands at their disposal to analyze how well optical systems function.

The group’s optical developments cover not only entire system technology, but also address individual manufacturing steps, such as the production of lenses and mirrors as well as coating technology for different wavelength ranges from X-ray to far infrared. For example, the institutes can manufacture high-precision mirror systems for various applications and wavelength ranges for space missions; they can also develop and characterize them for beamforming and deflecting mirrors for EUV lithography.

To produce optics and optical components, the institutes of the Fraunhofer Group for Light & Surfaces have various processes for shaping and coating technology. The spectrum ranges from ultra-precision processing for the production of metal mirrors, gratings and plastic-based lenses and lens arrays all the way to the replication of optical elements in mass production via injection molding technology and hot embossing processes.

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