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Optical Manufacturing Processes

Optics Manufacturing

I have hands-on experience and have worked in process engineering with optics of varying sizes, from 1.5 mm to 2.56 m in diameter and thickness as thin as 90 mm. My work spans diverse materials including glass, metals, gain crystals, and nonlinear and birefringent crystals, all with varying hardness levels from NaCl to Al2O3. These materials have been configured into flats, radii, prisms, cylinders, aspheres, multi-surfaces, and lightweight assemblies, among others. I've developed specialized tooling, fixtures, and handling processes for unique projects, and I’ve created testing methods to ensure the efficacy and quality of these optics. Furthermore, I designed and implemented a six-month apprentice program for a leading laser manufacturer that elevated new hires to the competence level of seasoned opticians. My training sessions have also been delivered to technicians at several major precision optics companies.

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

The Fraunhofer Group for Light & Surfaces focuses on the development of optical systems for diverse applications including lighting engineering, material analysis, and laser and measurement technology. They offer the complete process chain from design to production of customer-specific optical systems, handling everything from prototyping to final product manufacturing. Through comprehensive development and testing phases, these systems undergo rigorous evaluation before serial integration. The group’s institutes are equipped with specialized test benches and facilities to thoroughly analyze the functionality of optical systems.

The group's expertise extends beyond entire system technologies to individual manufacturing steps such as lens and mirror production and coating technologies for wavelengths ranging from X-ray to far infrared. For instance, they can produce high-precision mirror systems for various applications and develop and test beamforming and deflecting mirrors for EUV lithography used in space missions.

The Fraunhofer Group for Light & Surfaces employs various processes for shaping and coating technology to produce optics and optical components. These processes range from ultra-precision machining for metal mirrors and gratings to the mass replication of optical elements using injection molding and hot embossing techniques.

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