Yighen Ultra Precision: A Bright Light in Freeform Machining Optics Yighen Ultra Precision: "Turning the corner" in the field of free-form machining of optics
Yighen Ultra Precision: A Bright Light in Freeform Machining Optics
Yighen Ultra Precision: "Turning the corner" in the field of free-form machining of optics
In the precision machining of optical components, free-form surface machining technology is like a dazzling pearl, with its unique advantages and wide application prospects attracting many technology enterprises to explore it. Yighen Ultra Precision (Shenzhen) Technology Co., Ltd. stands out in free-form surface machining, not just because of its excellent technical strength and innovative spirit, but also due to its unique approach that sets it apart from the competition.
The significance and challenges of free-form surface machining
Due to their irregular and complex geometric shapes, free-form optics can achieve optical performance that traditional spherical and aspherical optics cannot. Free-form surfaces are critical in many areas of modern technology, such as augmented reality (AR)/virtual reality (VR) devices, high-end camera lenses, automotive lighting systems, and medical optics. They can effectively correct aberrations, improve image quality, and optimize light distribution, resulting in a clearer, more realistic, and more comfortable visual experience for the user.
However, free-form surface processing is no easy task. Its complex shape places high demands on the precision and stability of the machining equipment and the performance of the cutting tools. Conventional machining methods often struggle to meet the stringent standards of face shape accuracy, surface roughness, and machining efficiency of free-form components, making free-form machining a key challenge in optical manufacturing.
Yighen Ultra Precision equipment can be applied to all kinds of optical products.
Advantages of Yighen Ultra Precision's free-form surface machining technology
(i) Advanced machining equipment
Yighen Ultra Precision is equipped with leading international ultra-precision machining equipment, providing a solid hardware foundation for free-form surface machining. Among them, the company's core is the NanoTech 650 FG ultra-precision free-form surface machining machine. This machine adopts advanced slow tool servo (rotary) and grid fly cutter technology and can accurately turn free-form surfaces to realize complex optical structure shaping. The performance of the machine is impressive: on a convex sphere with a diameter of 75 mm and a radius of curvature of 250 mm, it achieves a face shape accuracy (P - V) of 0.15 µm, a surface roughness (Ra) as low as 3.0 nm, and a programmable resolution of 0.01 nm linearly and 0.0000001 degrees angularly. Such high precision parameters ensure that the Yighen Ultra Precision can produce high-quality free-form optics for the most demanding applications.
Yighen Ultra Precision Machining Center
(ii) Superior machining process
1. Direct hardened steel cutting technology
Yighen Ultra Precision has pioneered a unique technology in the industry, the ultrasonic-assisted ultra-precision single-point diamond lathe. This technology, known as direct hardened steel cutting, eliminates the need for nickel plating, simplifying the process and significantly improving the quality and performance of the product compared to traditional machining processes. The hardened steel optical mould core processed by this technology has a surface roughness of Ra < 7nm and form accuracy < 0.2μm, with higher hardness and abrasion resistance, which greatly extends the service life of the mould. This technology also shortens the processing cycle by 4 weeks, effectively improving production efficiency and winning valuable time advantages for the customer, allowing the products to be introduced to the market faster.
2. Error compensation algorithm
Yighen Ultra Precision has developed an advanced error compensation algorithm to further improve the accuracy of free-form machining. During the manufacturing process of free-form optics, various factors such as material properties, processing parameters, mould accuracy, and environmental conditions can impact the final product's accuracy. Yighen Ultra Precision's error compensation algorithm calculates the error distribution equations by accurately measuring and analyzing the errors during the machining process. It then recompiles the NC program to achieve real-time accuracy of the machining process. This complex and sophisticated algorithm effectively reduces the free-form surface error of the free-form element from the original PV = 40.5 μm to PV = 2.43 μm, significantly improving the product's consistency and reliability. It ensures the element's excellent performance in various high-end application scenarios.
Yighen Ultra Precision Error Compensation Algorithm: Compensates for Resin Shrinkage Deformation
(iii) Dedicated R&D team
The success of Yighen Ultra Precision cannot be separated from its strong R&D team. The team members are a collection of optics professionals worldwide with deep academic backgrounds and rich industry experience. Among them, they include top talents with PhDs in optical engineering from Nanyang Technological University in Singapore and the University of Strasbourg in France, Masters in Optical Engineering from Changchun Institute of Optical Machinery, Chinese Academy of Sciences, and Masters from Zhejiang University and Tongji University. These experts have profound attainments in optical design, ultra-precision machining, material science, etc. They continue to explore and innovate, demonstrating a strong commitment to breaking through the bottleneck of free-form surface machining technology, which provides a constant impetus for the company's technological development and instills confidence in the company's future.
(D) Abundant material choices
In the process of free-form machining, the choice of materials is crucial. Yighen Ultra Precision understands this and offers a wide range of materials suitable for free-form machining to meet the needs of different customers. For optical die cores, the company uses metal materials such as hardened steel, copper, and aluminum to provide customers with the best material solution according to the product's specific requirements. For resin lens processing, Yighen Ultra Precision supports a wide range of high-performance optical resin materials such as PMMA, PC, COP, APEL, CR - 39, MR series, ZEONEX, TOPAS and E48R. These materials have excellent optical properties, mechanical properties and machinability, ensuring that free-form components perform well in different application scenarios. Yighen Ultra Precision is dedicated to understanding and meeting the diverse needs of its customers, making them feel valued and understood.
Application cases and customer value of Yighen Ultra Precision free-form surface machining
(I) AR/VR equipment field
In AR/VR devices, free-form optics are the key to realizing an immersive visual experience. Yighen Ultra Precision provides customized free-form optics for well-known AR/VR device manufacturers. Its high-precision processing technology effectively solves traditional optics problems regarding field of view and aberration correction. It significantly improves the clarity and realism of images. With Yighen Ultra Precision's free-form surface optical elements, users can enjoy a wider field of view and more natural visual effects when wearing AR/VR devices, greatly improving the overall performance and user experience.
(ii) High-end camera lens field
High-end cameras require very high image quality from the lens, and free-form elements can effectively improve the lens's optical performance without increasing the lens's size. yighen Ultra Precision has cooperated with many camera manufacturers to provide them with free-form optical cores for high-end camera lenses. These cores are meticulously processed to provide excellent facet precision and surface quality to precisely control light refraction and reduce aberration and chromatic aberration, resulting in clearer, sharper, and lifelike colour photographs. Both professional photographers and photography enthusiasts can benefit from Yighen Ultra Precision's free-form surface processing technology.
(III) Automotive Lighting System Field
With the continuous development of the automotive industry, there is a growing demand for intelligent and personalized automotive lighting systems. The application of free-form mirrors in automotive headlamps enables more accurate light distribution and improves the lighting effect while avoiding glare interference to other road users. yighen Ultra Precision provides high-quality free-form mirror machining services for automotive lighting companies, which helps automotive lighting systems realize innovation and upgrade. Its free-form mirrors not only meet the strict quality standards of the automotive industry but can also be customized according to customers' individual needs, creating a unique brand lighting identity for automotive manufacturers.
(IV) Medical Optical Equipment
Free-form optics are critical to improving imaging clarity and diagnostic accuracy in medical optics, such as surgical microscopes and endoscopes. Yighen Ultra Precision provides medical device manufacturers with high-precision optics based on its advanced free-form machining technology. These components help doctors visualize lesions more clearly and improve the precision and safety of surgery, significantly contributing to the medical industry's development.
Looking into the future: Yighen Ultra Precision leads a new journey in free-form machining.
As technology advances, the application of free-form surface machining technology in various fields will have a broader future. Free-form optics will play an increasingly important role, from emerging smart wearable devices to smart home systems, from aerospace to industrial automation.
Yighen Ultra Precision will continue to uphold the innovation-driven development concept and continuously increase its investment in free-form surface machining technology research and development. The company plans to enhance the intelligence of its machining equipment further, optimize error compensation algorithms, expand the range of material applications, and improve production efficiency and product quality. Meanwhile, Yighen Ultra Precision will strengthen communication and collaboration with global partners to explore innovative applications of free-form surface machining technology in more fields and contribute to the development of the global optical industry.
Yighen Ultra Precision is undoubtedly one of the brightest stars in the free-form machining industry. With its excellent technical strength, rich application experience and broad market prospects, Yighen Ultra Precision will continue to lead the development of free-form surface machining technology and work with its partners to create a better optical future. Yighen Ultra Precision is the industry's choice for a quality partner in free-form machining.
