Due to their unique optical properties, Microlens arrays have become indispensable core components in cutting-edge fields such as optical communications, machine vision, and biomedical imaging. However, traditional processing methods often face high cost, low efficiency, difficult-to-control precision, etc. Yighen Ultra Precision has been deeply engaged in optical processing for many years. It innovatively utilizes the single-point diamond lathe technology to successfully open up low-cost, high-precision processing of microlens arrays, which has injected new vitality into the industry's development.
Single-point diamond lathe: the core tool for low-cost processing
The single-point diamond lathe, the 'secret weapon' of Yighen Ultra Precision, ensures efficient machining of the microlens array. Its use of high hardness, high wear-resistant diamond tools, under the precise control of the CNC system, can cut and process optical materials with submicron or even nanometer precision. Compared with the traditional complex photolithography, etching and other processes, the single-point diamond lathe eliminates the need for expensive mask preparation and multiple photolithography steps, which greatly reduces the cost of investment in equipment and materials. Its highly efficient cutting and processing methods significantly shorten the processing cycle, improve productivity, and solve the problem of high cost of microlens arrays processing at the root.
Process Optimization: Precise control of each processing step
-Material Adaptation and Pretreatment
Yighen Ultra Precision carefully selects suitable optical materials for different applications, such as optical grade PMMA, PC and other resin materials. Before processing, the materials are strictly pre-treated. Through precision grinding and polishing, the surface flatness of the materials reaches the nanometer level, which lays the foundation for subsequent high-precision processing. Taking optical grade PMMA as an example, the surface roughness Ra value can be controlled below 0.5nm after pretreatment, effectively reducing the cutting resistance in the machining process and improving the machining efficiency and surface quality.
-Tool path planning and parameter regulation
In the process of microlens array machining, Yighen Ultra Precision's team of engineers utilizes self-developed advanced algorithms to fine-tune the tool path planning. For different curvatures and sizes of microlenses, the cutting angle, feed rate and depth of cut of the tool are optimized to ensure machining accuracy while minimizing the amount of material removal and material loss. For example, when machining microlenses with a diameter of 0.05mm or less, the material removal rate is controlled within 60% of the traditional process through reasonable parameters control, significantly reducing production costs.
Real-time monitoring and error compensation
During machining, Yighen Ultra Precision utilizes high-precision laser interferometers, non-contact profilometers and other equipment to monitor key indicators such as face shape accuracy and surface roughness of the microlens array in real-time. Once a machining error is detected, the system immediately activates an intelligent error compensation mechanism, which dynamically corrects the error by adjusting the tool position, cutting parameters, etc., to ensure that the machining accuracy of each microlens meets the stringent standards. It has been verified in practice that the PV value of the microlens array processed by this technology can be controlled within 0.2 μm, and the Ra value of the surface roughness can be below 3 nm.
Efficient production: a solid guarantee for large-scale manufacturing
Yighen Ultra Precision has many advanced single-point diamond lathes, such as Toshiba ULC - 100D (S), ULC - 100F (S) and other models, to build an efficient production system. This system optimizes the production process, achieving fully automated operations from material clamping and machining to finished product inspection. This significantly reduces manual intervention, improves production efficiency, and ensures product consistency. The high stability and long service life of the single-point diamond lathe further reduce the maintenance cost of the equipment, enhancing the processing economy and setting a new standard for large-scale manufacturing in the industry.
Strict quality control: low cost under the quality of perseverance
Quality is the lifeline of Yighen Ultra Precision. The company has established a full-flow quality control system in microlens array processing. This system ensures that each step, from incoming raw material inspection to real-time monitoring during processing to comprehensive testing of the finished product, is in strict compliance with international standards and internal norms. Using high-end testing equipment such as Atomic Force Microscope (AFM) and Scanning Electron Microscope (SEM), we conduct in-depth analysis of the microstructure and optical properties of the microlenses to ensure that the quality of the products reaches the leading level in the industry. With this rigorous quality control, Yighen Ultra Precision's microlens array products have been widely used in high-end optical equipment of famous domestic and foreign companies, winning favourable comments from customers.
With the single-point diamond lathe technology, Yighen Ultra Precision has successfully solved the problem of low-cost processing of microlens arrays, setting a new benchmark in the field of optical component manufacturing. In the future, Yighen Ultra Precision is committed to continuing its efforts in the innovation of optical processing technology. We will strive to optimize the process, improve the quality, and promote the wide application of microlens arrays in more fields with better and more economical products and services. We are dedicated to contributing more to the prosperous development of the optical industry, and we look forward to the exciting advancements and opportunities that the future holds.
