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Optics Express

Optics Express

  • Editor: Andrew M. Weiner
  • Vol. 21, Iss. 3 — Feb. 11, 2013
  • pp: 3557–3572

Rapid fabrication of miniature lens arrays by four-axis single point diamond machining

Brian McCall and Tomasz S. Tkaczyk  »View Author Affiliations

Optics Express, Vol. 21, Issue 3, pp. 3557-3572 (2013)

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A novel method for fabricating lens arrays and other non-rotationally symmetric free-form optics is presented. This is a diamond machining technique using 4 controlled axes of motion – X, Y, Z, and C. As in 3-axis diamond micro-milling, a diamond ball endmill is mounted to the work spindle of a 4-axis ultra-precision computer numerical control (CNC) machine. Unlike 3-axis micro-milling, the C-axis is used to hold the cutting edge of the tool in contact with the lens surface for the entire cut. This allows the feed rates to be doubled compared to the current state of the art of micro-milling while producing an optically smooth surface with very low surface form error and exceptionally low radius error.

© 2013 OSA

OCIS Codes
(220.0220) Optical design and fabrication : Optical design and fabrication
(220.1920) Optical design and fabrication : Diamond machining
(220.3630) Optical design and fabrication : Lenses
(220.4610) Optical design and fabrication : Optical fabrication

ToC Category:
Optical Design and Fabrication

Original Manuscript: November 8, 2012
Revised Manuscript: January 19, 2013
Manuscript Accepted: January 22, 2013
Published: February 5, 2013

Brian McCall and Tomasz S. Tkaczyk, "Rapid fabrication of miniature lens arrays by four-axis single point diamond machining," Opt. Express 21, 3557-3572 (2013)

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