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Optimax Capabilities

Founded in 1991, Optimax is a world-class manufacturer of precision optics. With more than 200 skilled opticians and a modern 120,000 sq. ft. facility, Optimax is the largest prototype optics manufacturer in the United States. Optimax produces a wide range of optical components including:

High Precision Optics Manufacturer

Optimax is dedicated to supporting projects that require:

Small Volume • High-Quality • Quick Delivery

We have built a facility with diverse capabilities for making a wide variety of optical components:

  • Up to 500 mm in diameter
  • From a wide range of optical materials for specialized applications from the deep ultraviolet (DUV) to the far infrared (IR), including:
    • All optical glasses and fused silica
    • Optical crystals – e.g. CaF2, BaF2, ZnS, ZnSe, Ge, Si, Sapphire, MgO2
    • Optical ceramics – e.g. Spinel, Alon, Clearceram, Zerodur

Optimax capabilities incorporate a wide range of manufacturing technologies from which we can choose the best process for your requirements. Fabrication capabilities range from conventional machinery to highly deterministic CNC machining, including:

  • CNC subaperture polishing for aspherical and toroidal surfaces
  • Magneto Rheological Finishing (MRF)
  • Optimax patented VIBE polishing
Optics Manufacturing Robots

Optics for HIGH POWER

Optimax has developed superior fabrication and coating capabilities for advanced optics designed for use in systems for:

Optimax Tools

Manufacturing Tolerance Chart
Test Plate Library
Preferred Glass List
Aerospace Glass List

Optimax Manufacturing Limits

Optimax utilizes deterministic CNC machine tools for predictable removal rates and adherence to tight tolerances. To control centration, precision tools maintain the optical axis.

General Comments on Manufacturing Limits

  • This represents a general list of soft limits and is intended for reference only.
  • As requirements move closer to a min or max shown the more challenging the part will be.
  • Certain combinations may not be possible – Choosing Max Sag and Min Diameter on concave surfaces for example.
  • Interferometric testing of aspheres is extremely case specific. The slower the onset of departure, the more likely interferometric testing is possible.
  • During manufacturing the lens is oversized in diameter. Be aware, forms well behaved within clear aperture may turn exotic or undefined just beyond final diameter.

Manufacturing Limits for Aspheric Surfaces

Based on Form Error Tolerance

Form Error > 2μm Lower Resolution Profilometry (2-D)1
Attribute
Minimum
Maximum
Diameter (mm) 3 250
Local Radius (mm) -8 (Concave)
Sag (mm) 0 502
Departure (mm) 0.01 20
Included Angle (°) 0 120
Form Error 0.5 – 2μm Higher Resolution Profilometry (2-D)1
Attribute
Minimum
Maximum
Diameter (mm)3 3 250
Local Radius (mm) -12 (Concave)
Sag (mm) 0 252
Departure (mm) 0.01 20
Included Angle (°) 0 150
Form Error < 0.5μm Interferometry with Stitching (3-D)
Attribute
Minimum
Maximum
Diameter (mm)3 3 250
Local Radius (mm) -13 (Concave)
Sag (mm) 0 252,4
Departure (mm) 0.002 1
Included Angle (°) 0 120+5
1Typical metrology is Zygo MetroPro plots for interferometry
2For concave surfaces the maximum may be smaller, limited by tool clearance first. Short radii have lower maximums
3Larger diameters can be accommodated using multiscan fusion
4Total sag allowed is a function of diameter, determined by fringe resolution of the interferometer
5Very basic forms (paraboloid, ellipsoid) can have higher included angles

Thin Film Coating Manufacturing Limits

Coating Capabilities
Attribute
Minimum
Maximum
Diameter 3mm 500mm
Wavelength 193nm 5500nm
Use Environment Vacuum >95% RH
Durability Moderate abrasion Severe abrasion
Measurement 68°, s, p, average polarization
Laser Damage Threshold 1064nm: >30J/cm2@10ns, >1MW/cm2CW
Layers 1 200
* Soft Tolerancing Units **Stitching/CGH dependent

Above are manufacturing limits and tolerances specific to thin film coating. For more detailed information, please contact sales@optimaxsi.com.

General Comments on Manufacturing Limits

  • This represents a general list of soft limits and is intended for reference only.
  • As requirements move closer to a min or max shown fabrication becomes more difficult.
  • Certain combinations are unattainable, e.g. 3mm convex radius with 100mm length.
  • Certain configurations add significant fixturing costs, e.g. crossed axis cylinders, cylinders/spheres.
  • Interferometric testing of cylinders is somewhat case specific. Aperture coverage is often limited by the range of diffractive nulls available.
  • Length is always the dimension along the plano axis and width is the dimension across the power axis.

Manufacturing Limits for Cylindrical Surfaces Based on Manufacturing Method

Rod or Arbor
Attribute
Minimum
Maximum
Length (mm) 3 5001
Width (mm) Radius dependent 2 < 2x Radius
Cylinder Radius (mm) – Convex Only 2 150
X-Y
Attribute Minimum Maximum
Length (mm) 3 300
Width (mm) 2 300
Cylinder Radius (mm) 10
Concave sag to flat (mm) 0.1002 =Radius
1This is at minimum radius and width. The part-specific minimum will grow in proportion to radius.
2Flat surfaces lead to scratching problems and polisher contact issues. For both practical and economic reasons consider plano here.

Manufacturing Limits for Freeform Surfaces

Attribute
Tolerancing Limit*
Diameter (mm) +0, -0.010
Center Thickness (mm) ± 0.050
Irregularity – Interferometry
(HeNe fringes)
0.1**
Irregularity – Profilometry (μm) ±1.0
Wedge Lens – ETD (mm)
TBD
Surface Roughness (Å RMS) 10
* Soft Tolerancing Units **Stitching/CGH dependent

General Comments on Manufacturing Limits

    • This represents a general list of soft limits and is intended for reference only.
    • As requirements move closer to a min or max shown, the more challenging the part will be.

Manufacturing Limits for
Prism Surfaces

Attribute
Minimum
Maximum
Diameter (mm) 3 300
Thickness 1 150
Aspect Ratio1 1 502
1Diameter divided by thickness
2This represents highest values obtained. When at maximum other minimums (irregularity) may not be possible. Will be smaller with less well behaved materials.

General Comments on Manufacturing Limits

  • This represents a general list of soft limits and is intended for reference only.
  • As requirements move closer to a min or max shown, the more challenging the part will be.
  • During manufacturing, the lens is over-sized in diameter.

Manufacturing Limits for Spherical Surfaces

Based on Form Error Tolerance

Attribute
Minimum
Maximum
Diameter (mm) 3 400
Radius (mm) ±1 2
Aspect Ratio (Diameter/Center Thickness) <1:1 30:1
Included Angle (°) 0 2103
1Limited by machine envelope
2Metrology dependent. Avoid 3-10 meter radii when possible, choosing to stay plano instead. It will be less expensive too.
3This represents highest values possible. Actual value possible depends on finished and metrology options available plus tolerance range available for a given part.

Here are manufacturing limits and tolerances specific to optical aspheres, prisms, cylinders and spheres. For more detailed information on any attribute, please contact sales@optimaxsi.com.

High Precision Custom Optics

Optimax trains its employees to be inspectors first to support our Lean manufacturing environment. Opticians measure and certify their work with metrology instrumentation to assure that it conforms to specifications. Optimax instrumentation includes the most advanced phase measuring interferometry, which allows us to make surface accuracy measurement to lambda / 50.

  • 100% inspection of the products it manufactures
  • <3 standard levels of manufacturing tolerances
  • Written QA data with all prototype orders
  • ISO 9001:2015 certified and compliant with MIL-I-45208A

To ensure that each customer receives only product that conforms to specifications, Optimax performs a 100% inspection of all the optics we manufacture. Written QA measurement documentation is systematically supplied with all prototype orders. Upon request, such data can also be supplied for production orders. Optimax Quality procedures and standards are consistent with ISO 9001:2015 certification.

Verification Data Package includes:
Verification Data Package includes:

Note: Irregularity verified with best fit transmission sphere (No Stitching). Data provided electronically.

Verification Data Package Options:

(One of the Following)

Contact a sales engineer for further information

ISO Certification
Military Certification
Packaging Options

Expedited Optics Manufacturing & Delivery

With years of experience perfecting its Lean manufacturing processes, Optimax is uniquely qualified to offer fast, on-time deliveries.

Optimax is the world’s leading rapid delivery manufacturer of custom optical components. Since its founding, Optimax has recognized that industries and institutions need fast deliveries of high quality, precision optics and has invested more than 15 years perfecting highly reliable and effective Lean processes. To learn more about these and other Optimax innovations, please visit About Optimax.

Customers trust Optimax to reliably manufacture their most complex optics on time. In the unlikely event that an expedited delivery is late, Optimax policy is to refund any unearned premium.

When you need optics fast and right!

Optimax excels at grinding, polishing and coating precision optics quickly and reliably. We can deliver high precision optics in as little as one week.

Optimax Capabilities

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