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.
Spheres, the most common type of optic, have at least one surface that is a segment of a ball. A spherical lens is made with a particular radius of curvature. This radius can be as short as 1mm or very long, to where plano is an infinite radius. Spheres are found in camera lenses, machine vision systems, laser beam shaping, and similar applications.
We’ll walk you through the process, and invite you to visit the Resource Library for technical resources at every step.
Specifying spheres begins with choosing an optical material. Next, the designer selects a diameter, thickness and surface radii. Finally, mechanical and optical attributes are toleranced in accordance with the designer’s performance requirements and the manufacturer’s capabilities
Reducing the range of a tolerance will add manufacturing cost. The task in selecting tolerances is to minimize cost while ensuring good optical performance. The Cost of Tolerancing gives valuable insight into optimally tolerancing optical components, written in collaboration between an optical engineer, an optics manufacturer, and a metrologist.
For more information on our sphere manufacturing please see:
Optimax makes spheres from optical materials such as glass, fused silica, crystals and ceramics for UV, Visible and IR applications using proprietary “grind and shine” techniques to produce low scatter surfaces. Whether to prepare lens surfaces or to correct wedge, CNC machine tools are employed throughout the spherical fabrication process.
For more information please see:
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 |
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 |
Attribute |
Minimum |
Maximum |
| Diameter (mm) | 3 | 300 |
| Thickness | 1 | 150 |
| Aspect Ratio1 | 1 | 502 |
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 |
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 |
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 |
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 |
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 one of the largest test plate libraries for making spheres. These test plates are certified to +/- 0.01% of radius. As required, Optimax can make test plates for special radii.
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
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