Optics and photonics are considered as an enabling technology for innovations in other technological fields (e. g. astronomy, medicine, military, …). Their first applications date back to jewellery processing in ancient times. In the medieval age Vikings on Gotland (1050) buried the Visby lenses. They have a quality of workmanship and imaging comparable to a high quality lens made in the mid-20th century. The specific use of spectacles to correct long-sightedness or presbyopia is known from the 13th century. Around the transition from the 16th to the 17th century, the microscope and the telescope were invented, combining several lenses for the first time. This shows that the exploitation of the optical properties of materials can be dated back very early in human history. In particularly, today`s optics industry is still based on personal knowledge which results in a relatively workmanship production environment. The challenges of globalisation and the current pandemic situation demonstrate that increasing the degree of automation is a possible way to keep a leading position in the market. This is not only important due to the high quality of optical components but also by enabling competitive prices for production through reducing the labour costs. The third industrial revolution established the digitalisation of production and the usage of CNC-machinery. In most industries including optics industries this is the status quo of production. The target of industry 4.0 and internet of things is to lead into a new industrial revolution. The German government developed the buzzword “Industrie 4.0” (eng. Industry 4.01 ). This concept includes the contradiction of mass production and production according to individual customer requests. This should be carried out by connecting all production units with the goal of an intelligent factory. Among other things this includes seamless monitoring of the manufacturing processes along all steps and remote access to involved machines. A further target is manufacturing under the constraint of a small batch size down to one piece. This publication aims to present the current situation in the manufacturing of optical components and compare this with manufacturing of metallic components. It will outline, which measures are necessary to ensure a comprehensive transformation of the optical industry in accordance with the Industry 4.0 idea and which benefits can be expected.
{"title":"Industry 4.0 in the fabrication of optical components: development, presence, and requirements","authors":"Stefan Anthuber, Michael F. Benisch, R. Rascher","doi":"10.1117/12.2595037","DOIUrl":"https://doi.org/10.1117/12.2595037","url":null,"abstract":"Optics and photonics are considered as an enabling technology for innovations in other technological fields (e. g. astronomy, medicine, military, …). Their first applications date back to jewellery processing in ancient times. In the medieval age Vikings on Gotland (1050) buried the Visby lenses. They have a quality of workmanship and imaging comparable to a high quality lens made in the mid-20th century. The specific use of spectacles to correct long-sightedness or presbyopia is known from the 13th century. Around the transition from the 16th to the 17th century, the microscope and the telescope were invented, combining several lenses for the first time. This shows that the exploitation of the optical properties of materials can be dated back very early in human history. In particularly, today`s optics industry is still based on personal knowledge which results in a relatively workmanship production environment. The challenges of globalisation and the current pandemic situation demonstrate that increasing the degree of automation is a possible way to keep a leading position in the market. This is not only important due to the high quality of optical components but also by enabling competitive prices for production through reducing the labour costs. The third industrial revolution established the digitalisation of production and the usage of CNC-machinery. In most industries including optics industries this is the status quo of production. The target of industry 4.0 and internet of things is to lead into a new industrial revolution. The German government developed the buzzword “Industrie 4.0” (eng. Industry 4.01 ). This concept includes the contradiction of mass production and production according to individual customer requests. This should be carried out by connecting all production units with the goal of an intelligent factory. Among other things this includes seamless monitoring of the manufacturing processes along all steps and remote access to involved machines. A further target is manufacturing under the constraint of a small batch size down to one piece. This publication aims to present the current situation in the manufacturing of optical components and compare this with manufacturing of metallic components. It will outline, which measures are necessary to ensure a comprehensive transformation of the optical industry in accordance with the Industry 4.0 idea and which benefits can be expected.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125606648","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In this paper we present a feasible variant of a device for in-process roughness measurement during an optical polishing process. The system, already presented as Tirm respectively I-Tirm, has been technically varied and can now be integrated into almost any lever polishing process with little effort. This enables new possibilities regarding real-time optical manufacturing process monitoring and optimization.
在本文中，我们提出了一种可行的变型装置，用于光学抛光过程中的过程粗糙度测量。该系统，已经分别提出了tim i - tim，已经在技术上变化，现在可以集成到几乎任何杠杆抛光过程中，只需很少的努力。这为实时光学制造过程监控和优化提供了新的可能性。
{"title":"In-process surface roughness measuring device for information-based real-time polishing process adjustment and optimization","authors":"D. Moszko, O. Faehnle, C. Vogt, D. Kim","doi":"10.1117/12.2596034","DOIUrl":"https://doi.org/10.1117/12.2596034","url":null,"abstract":"In this paper we present a feasible variant of a device for in-process roughness measurement during an optical polishing process. The system, already presented as Tirm respectively I-Tirm, has been technically varied and can now be integrated into almost any lever polishing process with little effort. This enables new possibilities regarding real-time optical manufacturing process monitoring and optimization.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"87 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124991583","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Atmospheric Plasma Jet Machining is performed on Borosilicate Crown Glass. A fluorine containing plasma jet is suitable for the etching of the material. A substrate surface temperature of about 325°C during processing is necessary for a controlled removal. The figure error can be corrected by a dwell time based deterministic process. The resulting surface roughness depends on the surface temperature of the processed sample.
{"title":"Atmospheric plasma jet machining of an optical element made from borosilicate crown glass","authors":"H. Müller, G. Böhm, T. Arnold","doi":"10.1117/12.2593591","DOIUrl":"https://doi.org/10.1117/12.2593591","url":null,"abstract":"Atmospheric Plasma Jet Machining is performed on Borosilicate Crown Glass. A fluorine containing plasma jet is suitable for the etching of the material. A substrate surface temperature of about 325°C during processing is necessary for a controlled removal. The figure error can be corrected by a dwell time based deterministic process. The resulting surface roughness depends on the surface temperature of the processed sample.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"20 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127752511","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The evolution of the old standard DIN 3140 for the tolerances of surface form deviations to the actual standard ISO 10110-5 introduces a more complex description of the form deviations and their tolerances. The drawing standard ISO 10110-5 is accompanied by the measurement standard ISO 14999-4, that complements the old test glass measurements by interferometric test methods. The different types of surface deformations have different impact on the performance of an optical system, and the selected tolerances must limit the image degradation within the specified limits. For some specific applications the most appropriate description of the relevant surface deformation is not yet foreseen in the actual standard, but future versions of the standard might include reasonable extensions.
{"title":"Tolerances for surface form deviations","authors":"E. Langenbach","doi":"10.1117/12.2595162","DOIUrl":"https://doi.org/10.1117/12.2595162","url":null,"abstract":"The evolution of the old standard DIN 3140 for the tolerances of surface form deviations to the actual standard ISO 10110-5 introduces a more complex description of the form deviations and their tolerances. The drawing standard ISO 10110-5 is accompanied by the measurement standard ISO 14999-4, that complements the old test glass measurements by interferometric test methods. The different types of surface deformations have different impact on the performance of an optical system, and the selected tolerances must limit the image degradation within the specified limits. For some specific applications the most appropriate description of the relevant surface deformation is not yet foreseen in the actual standard, but future versions of the standard might include reasonable extensions.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"17 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121053765","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
We investigated a novel approach for building measurement routines for measuring free form optics including fiducials based on an intuitive semi-automatic teach-in mode that requires no programming skills. An initial software version for use with the MarForm MFU 200 Aspheric 3D multi-sensor precision optics measuring station was developed and tested. In this paper, we describe the structure and the workflow of the software and show measurement results of test samples.
{"title":"Highly flexible free form optics measurement using a semi-automatic teach in approach","authors":"T. Schröter, Simon Huhn, Merten Kuna, A. Beutler","doi":"10.1117/12.2593645","DOIUrl":"https://doi.org/10.1117/12.2593645","url":null,"abstract":"We investigated a novel approach for building measurement routines for measuring free form optics including fiducials based on an intuitive semi-automatic teach-in mode that requires no programming skills. An initial software version for use with the MarForm MFU 200 Aspheric 3D multi-sensor precision optics measuring station was developed and tested. In this paper, we describe the structure and the workflow of the software and show measurement results of test samples.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"95 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125766386","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Technical systems are constantly getting reduced in size while functions are to be improved. The requirements for hightech components exceed the feasible limits of production technologies. Integrated precision components must meet everincreasing demands with regard to optical and geometric properties. Conventional technologies of glass machining often cannot withstand these requirements. Grinding, lapping and polishing processes are realized on separate machines. Thus, the manual change of components between the machines and constraints in machine kinematics result in significant loss of accuracy as well as restrictions in design and functionality. To meet the requirements, ShapeFab developed a more efficient manufacturing process for high-precision components made of glass. All previously separated manufacturing steps are combined on one machine. By means of high-precision 5- axis CNC jig grinding and corresponding integration of CAD-CAM chain, processes of finest machining and polishing can be fully combined. This leads to application of optically effective surfaces to almost any geometrical element. In addition, the machining of complex geometries can be accelerated due to highly automated processes, even in low volume production. With our technology a new generation of components with structures from 300 μm is available. High-precision parts can be designed smaller, lighter and multifunctional. For example, fixing geometries can be directly integrated in optical functional and freeform areas. This allows the components to be integrated into the final application with μm-precision, even without fixtures or further adjustment elements. The whole technical system can be designed compactly and costs for additional mechanical components can be saved. Applications can be found in almost all areas of photonics. Especially requirements from the semiconductor industry, optics, medical technology and laser technology can be fulfilled.
{"title":"High-precision glass processing with innovative coordinate grinding technology","authors":"Anett Jahn, O. Seidel, A. Helming","doi":"10.1117/12.2595723","DOIUrl":"https://doi.org/10.1117/12.2595723","url":null,"abstract":"Technical systems are constantly getting reduced in size while functions are to be improved. The requirements for hightech components exceed the feasible limits of production technologies. Integrated precision components must meet everincreasing demands with regard to optical and geometric properties. Conventional technologies of glass machining often cannot withstand these requirements. Grinding, lapping and polishing processes are realized on separate machines. Thus, the manual change of components between the machines and constraints in machine kinematics result in significant loss of accuracy as well as restrictions in design and functionality. To meet the requirements, ShapeFab developed a more efficient manufacturing process for high-precision components made of glass. All previously separated manufacturing steps are combined on one machine. By means of high-precision 5- axis CNC jig grinding and corresponding integration of CAD-CAM chain, processes of finest machining and polishing can be fully combined. This leads to application of optically effective surfaces to almost any geometrical element. In addition, the machining of complex geometries can be accelerated due to highly automated processes, even in low volume production. With our technology a new generation of components with structures from 300 μm is available. High-precision parts can be designed smaller, lighter and multifunctional. For example, fixing geometries can be directly integrated in optical functional and freeform areas. This allows the components to be integrated into the final application with μm-precision, even without fixtures or further adjustment elements. The whole technical system can be designed compactly and costs for additional mechanical components can be saved. Applications can be found in almost all areas of photonics. Especially requirements from the semiconductor industry, optics, medical technology and laser technology can be fulfilled.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"89 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124083498","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
M. Kühnel, E. Langlotz, I. Rahneberg, D. Dontsov, J. Probst, T. Krist, C. Braig, A. Erko
SIOS Meβtechnik GmbH developed a universal interferometrical profilometer for 3D measurements of freeform optics topography. Due to the measurement principle using a scanning differential interferometer, no expensive and individually shaped reference optics are required. All optic shapes such as plane-,spherical-, and freeform-optics with local slopes up to 7 mrad and sizes up to 100 × 100 mm2 can be measured with sub-nanometer resolution. The capability of the setup has been proven by measurements of highly precise machined silicon mirrors (plane and spherical). A maximum of ± 3 nm peak-valley deviation between two subsequent measurements of a 30 mm × 100 mm plane mirror topography has been achieved, which proves a very good repeatability. Furthermore, measurement results show very good accordance with those from Fizeau interferometer measurements of this precision plane mirror. The maximum deviation was ± 10 nm, which is a hint to a very good accuracy of our measurements. Furthermore, form parameters such as the radii of spherical mirrors can be determined precisely due to the interferometer-based synchronous measurements of the x- and y- positions of the z- topography. A reproducibility of 1.4 × 10-4 of the radius measurements of a 29 m radius mirror was achieved, whereat the mirror was measured on different supports and in different orientations.
{"title":"Interferometrical profilometer for high precision 3D measurements of free-form optics topography with large local slopes","authors":"M. Kühnel, E. Langlotz, I. Rahneberg, D. Dontsov, J. Probst, T. Krist, C. Braig, A. Erko","doi":"10.1117/12.2593700","DOIUrl":"https://doi.org/10.1117/12.2593700","url":null,"abstract":"SIOS Meβtechnik GmbH developed a universal interferometrical profilometer for 3D measurements of freeform optics topography. Due to the measurement principle using a scanning differential interferometer, no expensive and individually shaped reference optics are required. All optic shapes such as plane-,spherical-, and freeform-optics with local slopes up to 7 mrad and sizes up to 100 × 100 mm2 can be measured with sub-nanometer resolution. The capability of the setup has been proven by measurements of highly precise machined silicon mirrors (plane and spherical). A maximum of ± 3 nm peak-valley deviation between two subsequent measurements of a 30 mm × 100 mm plane mirror topography has been achieved, which proves a very good repeatability. Furthermore, measurement results show very good accordance with those from Fizeau interferometer measurements of this precision plane mirror. The maximum deviation was ± 10 nm, which is a hint to a very good accuracy of our measurements. Furthermore, form parameters such as the radii of spherical mirrors can be determined precisely due to the interferometer-based synchronous measurements of the x- and y- positions of the z- topography. A reproducibility of 1.4 × 10-4 of the radius measurements of a 29 m radius mirror was achieved, whereat the mirror was measured on different supports and in different orientations.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"38 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133660397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
N. Voznesenskiy, Mariia Voznesenskaia, Lei Huang, M. Idir
Testing of an X-ray mirror by a point diffraction interferometer (PDI) D7 with two beams is described. Thanks to the two independent test and reference beams, mirrors metrology using the D7 coupled with accessory optics becomes straightforward and reliable. Therefore procedure of systematic error removal and sub-aperture measurements with stitching are simplified. In this paper, we describe the main technique to achieve high accuracy of stitching sub-aperture wavefronts, followed by further perspectives of the described instrument.
{"title":"Testing surface form of precision optics by a point diffraction interferometer with two beams","authors":"N. Voznesenskiy, Mariia Voznesenskaia, Lei Huang, M. Idir","doi":"10.1117/12.2595181","DOIUrl":"https://doi.org/10.1117/12.2595181","url":null,"abstract":"Testing of an X-ray mirror by a point diffraction interferometer (PDI) D7 with two beams is described. Thanks to the two independent test and reference beams, mirrors metrology using the D7 coupled with accessory optics becomes straightforward and reliable. Therefore procedure of systematic error removal and sub-aperture measurements with stitching are simplified. In this paper, we describe the main technique to achieve high accuracy of stitching sub-aperture wavefronts, followed by further perspectives of the described instrument.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122464815","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Manufacturing precision optics is a complex process chain, which requires many operations on different machines. This is combined with operator-dependent steps such as manual cleaning, loading and measuring. In order to realize this process chain on a smaller shop area and to achieve a higher level of automation we build an operator-independent polishing cell. In this cell, an ABB robot serves as the actuator handling the workpiece. We positioned the robot in the center of the polishing cell to operate several workstations, so the whole process chain works with one single actuator. This arrangement allows a smaller and cheaper system, since no additional handling is required.
{"title":"First steps towards an automated polishing process chain using one robot","authors":"S. Killinger, J. Liebl, R. Rascher","doi":"10.1117/12.2564840","DOIUrl":"https://doi.org/10.1117/12.2564840","url":null,"abstract":"Manufacturing precision optics is a complex process chain, which requires many operations on different machines. This is combined with operator-dependent steps such as manual cleaning, loading and measuring. In order to realize this process chain on a smaller shop area and to achieve a higher level of automation we build an operator-independent polishing cell. In this cell, an ABB robot serves as the actuator handling the workpiece. We positioned the robot in the center of the polishing cell to operate several workstations, so the whole process chain works with one single actuator. This arrangement allows a smaller and cheaper system, since no additional handling is required.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122885587","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This research is focused on the link between manufacturing parameters and the resulting mid-spatial frequency error in the manufacturing process of precision optics. The goal is to understand the generation mechanisms of mid-spatial frequency errors and avoid their appearance in the manufacturing process. Also, a simulation which is able to predict the resulting mid spatial frequency error from a manufacturing process is desired.
{"title":"Mid spatial frequency error prevention strategies for the grinding process","authors":"M. Pohl, R. Boerret, Olga Kukso, R. Rascher","doi":"10.1117/12.2565261","DOIUrl":"https://doi.org/10.1117/12.2565261","url":null,"abstract":"This research is focused on the link between manufacturing parameters and the resulting mid-spatial frequency error in the manufacturing process of precision optics. The goal is to understand the generation mechanisms of mid-spatial frequency errors and avoid their appearance in the manufacturing process. Also, a simulation which is able to predict the resulting mid spatial frequency error from a manufacturing process is desired.","PeriodicalId":422212,"journal":{"name":"Precision Optics Manufacturing","volume":"4 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130749315","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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