Year after year, program after program, Optimax continues to push the limits of possible in complexity, quality and speed for its customers.
Optimax excels at grinding, polishing and coating precision optics quickly and reliably. We can deliver high precision optics in as little as one week.
We’ll walk you through the process, and invite you to visit the Resource Library for technical resources at every step.
Optimax prism-related capabilities are listed below. Due to having more than three sides polished or complex coatings, these components require longer deliveries:
Optimax prism manufacturing capabilities available with one week delivery include:
Optical prisms are components with at least two polished plano surfaces separated by a wedge angle. These elements are used to reflect or refract light. Optical prisms can be found in dual channel instruments, anamorphic systems, imaging systems or any other application where beam steering and/or image manipulation is needed.
Below are basic guidelines for defining part geometry:
The angle is the inclination of the two surfaces and the thickness is a separation at some point. The separation only needs to be positionally defined at one location on the optic. Specifying the thickest edge provides the easiest access for measurement and is preferred by Optimax. The specification can be the thinnest edge or centerline thickness if desired.
The geometry of three-sided prisms is defined by two angles and an altitude. The third angle and sides then become references. Outer shapes (perimeters) are typically rectangular, round or elliptical but can be anything within Optimax’s shaping capabilities.
For more information please see:
Figure 1 shows the geometry of two-sided wedges can be defined by an angle and a thickness.
Image above: Minimum Specifications for Wedges
Optimax grinds and polishes prisms from various optical materials for UV, visible and IR applications for use in transmission or reflectance. Materials processed include:
Optimax utilizes deterministic CNC machine tools for complex shaping and a host of conventional processing techniques for chemomechanical planarization. Capabilities include:
Attribute |
Minimum |
Maximum |
| Diameter (mm) | 3 | 300 |
| Thickness | 1 | 150 |
| Aspect Ratio1 | 1 | 502 |
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 |
Attribute |
Minimum |
Maximum |
| Diameter | 3mm | 500mm |
| Wavelength | 193nm | 6000nm |
| 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 |
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 |
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 |
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 |
Attribute |
Prism Tolerancing Limit |
|---|---|
| Glass Quality (nd, vd) | Melt Rebalanced and Controlled |
| Diameter (mm) | +0, -0.010 |
| Center Thickness (mm)3 | ± 0.010 |
| Sag – Concave (mm) | ± 0.010 |
| Clear Aperture | 100%4 |
| Power5 | 0.1 HeNe fringes6 |
| Irregularity – Interferometry (HeNe fringes)7 | 0.18 |
| Wedge Prism (window) – ETD (mm)9 | 0.00210 |
| Bevels – Face Width @ 45° (mm)11 | sharp |
| Scratch – Dig (MIL-PRF-13830B)12 | 10 – 5 |
| Surface Roughness (Å RMS)13 | 4 |
Attribute |
Cylinder Tolerancing Limit |
|---|---|
| Glass Quality (nd, vd) | Melt Rebalanced and Controlled |
| Length and width (mm) | +0, -0.020 |
| Center Thickness (mm)3 | ± 0.020 |
| Sag – Concave (mm) | ± 0.020 |
| Clear Aperture | 100%4 |
| Radius5 | ± 0.1% or 3 HeNe fringes6 |
| Irregularity – Interferometry (HeNe fringes)7 | 0.18 |
| Irregularity – Profilometry (μm) | ± 0.5 |
| Plano Axis Wedge – ETD (mm) | 0.00512 |
| Cylinder Axis Decentration – TIR (mm)9 | 0.01010 |
| Axial Twist Angle (arcminutes) | 3 |
| Bevels – Face Width @ 45° (mm)11 | 0/0mm max |
| Scratch – Dig (MIL-PRF-13830B)12 | 10 – 5 |
| Surface Roughness (Å RMS)13 | 5 |
Attribute |
Asphere Tolerancing Limit |
|---|---|
| Glass Quality (nd, vd) | Melt Rebalanced and Controlled |
| Diameter (mm) | +0, -0.010 |
| Center Thickness (mm)6 | ± 0.010 |
| Sag – Concave (mm) | ± 0.010 |
| Clear Aperture | 100%7 |
| Vertex Radius8 | ± 0.1% or 3 HeNe fringes9 |
| Irregularity – Interferometry (HeNe fringes)10 | 0.111 |
| Irregularity – Profilometry (μm)10 | ± 0.5 |
| Wedge Lens – ETD (mm) | 0.00212 |
| Bevels – Face Width @ 45° (mm)13 | ± 0.05 |
| Scratch – Dig (MIL-PRF-13830B)14 | 10 – 5 |
| Surface Roughness (Å RMS)15 | 10 |
Attribute |
Sphere Tolerancing Limit |
|---|---|
| Glass Quality (nd, vd) | Melt Rebalanced and Controlled |
| Diameter (mm) | +0, -0.010 |
| Center Thickness (mm)4 | ± 0.020 |
| Sag – Concave (mm) | ± 0.010 |
| Clear Aperture | 100%5 |
| Radius (mm)6 | ± 0.0025 or 1 HeNe fringe7 |
| Irregularity (HeNe fringes)8 | 0.059 |
| Wedge Lens – ETD (mm) | 0.00210 |
| Bevels – Face Width @ 45° (mm) | ± 0.0511 |
| Scratch – Dig (MIL-PRF-13830B)12 | <10 – 5 |
| Surface Roughness (Å RMS) | 313,14 |
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.
Optimax has phase shifting interferometers for precision measurement of flatness plus autocollimators and a Wild Goniometer for precision measurement of angles. Optimax makes transmission flats for interferometric testing of surface irregularity to 50th wave.
Optimax’s R&D department is continuously looking for ways to improve our fabrication process and produce higher quality optics. Our current research projects are designed to meet future market needs, such as:
For more information please see Optimax Innovation or contact sales@optimaxsi.com.
Free-form surfaces are quickly becoming a desired and necessary shape for many refractive and reflective optical
systems. Some examples of free-form shapes are toroids, ogives, and other conformal windows. In this paper, we will discuss the round-robin study of surface irregularity measurements of a free-form toroidal window
Freeform optical systems are becoming increasingly common due to new design and manufacturing methods. We present an example compact freeform optical system and describe considerations for transfer of the prescription of freeform surfaces for fabrication
Monolithic multi-surface telescopes combined with freeform optical surfaces provide improvements in optical performance in a smaller footprint as compared to systems with spherical surfaces, while providing superior mechanical stability to traditional telescope assemblies. Three different monolithic telescope concepts, in different configurations and optical performance were produced as proof of concepts
With optical technology and design advances, larger freeform optics are increasingly sought after by consumers for an expanding number of applications. This paper will present some of the challenges and solutions of extending freeform polishing capabilities from approximately 150 mm diameter parts to a component of over 500 mm in diameter
Opticians have for years kept polishing pitch in electrified containers called “pitch pots” that keeps it in at an elevated temperature. By insulating the top of a pitch pot, it will impact the temperature, which we will explore in this paper
This work presents an overview of the Segmented Aperture Interferometric Nulling Testbed (SAINT), a project that will pair an actively-controlled macro-scale segmented mirror with the Visible Nulling Coronagraph (VNC).
This explores quick predictive methods for calculating potentially risky stresses in cemented doublets underdoing temperature change that agrees well with finite element analysis. It also provides guidelines for avoiding stress concentrations
Optical designers assume a mathematically derived statistical distribution of the relevant design
parameters. Presented are measured distributions using
lens manufacturing data to better inform the decision-making process.
Optical designers assume a mathematically derived statistical distribution of the relevant design parameters. However, there may be significant differences between the assumed distributions and the likely outcomes from manufacturing.
Hard ceramic conformal windows and domes provide challenges to the optical fabricator, due to the material hardness, polycrystalline nature, and non-traditional shape. Creative optical fabrication techniques, including VIBE™, help produce these types of optics cost-effectively
Sapphire poses very difficult challenges to optical manufacturers due to its high hardness and anisotropic properties. These challenges can result in long lead times and high prices. Optimax is developing a high speed, cost effective process to produce such windows.
When manufacturing precision optical surfaces of relatively larger sizes it is critical to understand the thermal stability of the substrate material. The material properties associated with thermal homogenization are commonly reviewed and soak schedules are created.
Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. The flexibility is unparalleled and has opened the design space to enable features like undercuts and internal channels.
Improvements to sensing hardware and image processing for airborne optical systems have inspired designers to propose new optics and windows to be: more precise, conformal/freeform and multi-functional.
There are many decisions to make when designing, specifying, manufacturing, and testing optical components for high-energy laser systems — each is a potential failure mechanism that must be understood and controlled
Optimax has placed emphasis on refining the deterministic form correction process. By developing many of these procedures in house, changes can be implemented quickly and efficiently in order to rapidly converge on an optimal manufacturing method
Complete freeform optical fabrication process that includes ultrasonic generation of hard ceramic surfaces, high speed VIBE polishing, sub-aperture figure correction of polycrystalline materials, finishing and final testing of freeform surfaces
Optimax’s sapphire production process achieves significant improvement in cost by the implementation of a controlled grinding process to present the best possible surface to the polishing equipment
Three, four, and five-axis machining centers are used to grinding, polishing, and shaping the lenses with diamond tooling. Optimax now has five times more equipment and has added a third shift, increasing grinding and polishing productivity.
The concept for polishing optical elements with a process called VIBE is presented, application to non uniformly sloped optics such as aspheric shapes is detailed, and initial results on spherical surfaces are presented
With increasing demand for deep UV applications, special considerations must be taken to produce the optics. Specifically, as the wavelength of incident light decreases, the importance of smooth surfaces increases.
The VIBE™ process is a full aperture, conformal polishing process incorporating high frequency and random motion designed to rapidly remove sub-surface damage in a VIBE pre-polish step and eliminate mid-spatial frequency (MSF) errors in a VIBE finishing step.
Kate Medicus, Ph.D., Metrologist speaks on Freeform optical manufacturing and testing processes for IR conformal window and domes. This talk will include an overview of current freeform manufacturing and testing processes for producing freeform surfaces
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.
Optimax excels at grinding, polishing and coating precision optics quickly and reliably. We can deliver high precision optics in as little as one week.
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