Five-axis CNC Machining Optical Industry Precision Parts Process Guide

Optical precision CNC machining is essential to the creation of the modern optical industry. We use CNC to machine optical precision parts. At DONGGUAN YIFENG METAL, we provide 3-axis and 5-axis CNC machining. Optical parts are becoming more and more complex and therefore need to be handled. What followed was a new era of optical precision machining. When creating non-complex optical parts, we have several common methods. It requires polishing and normal grinding procedures. However, we can only partially create complex optical parts using these conventional methods. This is because they lack dimensional accuracy. In this case, our team of experts opted to use multi-axis machining.

Miniature and aspheric optical components often require very tight tolerances. Fortunately, the precision cutting process provides this required precision. They use diamond tools on ultra-precision tools to achieve this. So we end up with tight tolerances and a high surface finish. We use this method to achieve proper dimensional accuracy of optical parts and their molds. Here's further insight into this.


What are the ultra-precision production methods for optical parts?

There is an ideal way to fabricate complex micro-optical components. This is while achieving first-class surface quality down to a fraction of a micron Ra. It requires the use of ultra-precision tools and diamond cutters. Top-level expertise is required to obtain freeform surfaces, complex geometries and true 3D parts. We sometimes have to use some unique multi-axis machining methods.

Mechanics employ very few methods in optical precision machining. These include laser machining, EDM, grinding, micro-dicing and silicon etching. Optical machining requires machining on flat and freeform optical surfaces. Micro-dicing is the only way to achieve the desired feature size, precision and precision on both optical surfaces.

What are the tool factors for optical precision machining?

Two main factors determine the production quality of optical parts. These are the tip roundness and sharpness of the knife. Therefore, we had to include special tool geometries. These include ball nose end mills, diamond micro end mills and other turning and forming tools. There are several ultra-precision cutting methods for optical parts. They are fly cutting, end mill cutting, plunge cutting and rapid tool cutting.

Our team of experts sometimes combine vibration-free CNC machines with compact tool holders and fixtures. This allows the single point diamond cutting tool to effectively scrape material from the workpiece. This method ensures that very high and concentrated cutting forces act on the workpiece. As a result, we end up with virtually no dents elsewhere, while maintaining perfect shape accuracy and surface finish. This enables us to achieve optical precision machining.

What is single point diamond turning? Optical Precision Machining

We apply this type of machining when we want to obtain rotationally symmetrical optical parts. It is one of the most efficient cutting processes. This method achieves high cutting speed and high surface finish at Ra less than 5. The tools we use in this method take into account the accuracy of the part in production.

Our experts often calculate the tool radius and the compensation of the entire tool during machining. Furthermore, we have to be very careful when dealing with precision in the sub-micron range. This involves controlling the waviness of the tool to a level of 0.1um of the tool radius. At the same time, if we need a simpler surface structure, we use plunge cutting with a pointed tool. These methods help us achieve optical precision machining.

CNC Milling

CNC milling is a great choice when machining complex surface geometries. We sometimes use it to achieve the surface treatment of freeform surfaces. Examples of optical components we are able to manufacture include camera lenses and vehicle lighting prototypes. When machining these parts, we need at least one 3-axis CNC machine. In contrast, we need a 5-axis machine to obtain precise optical surface features. In this case, we used three main diamond CNC milling tools. They are end mills, fly cutting and ball nose end mills.

Ball end mills are critical when working with free-form features. This is because they can handle geometries up to 0.5mm. Our professional machining services allow us to achieve interior angle accuracies up to R0.1-R0.15mm. Fly cutting tools are ideal for pocket cutting. Also, we can use them when dealing with planes. For example, we use it to machine laser mirrors and pyramid parts.

What is the key role of optical precision machining in the modern world?

It is worth noting that the demand for optical components is currently at a peak. This is accompanied by a growing consumer market for electronic components. Of note is the use of camera lenses in DSLRs, smartphones, and printer scanning mirrors. This presents a mission challenge to the market. The main question is how to cost-effectively produce free-form optical components. Fortunately, precision machining allows us to achieve this. We ended up replacing the normal camera lens with a single free-form mirror part. This makes it compact while saving production costs.
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