Innovations in Large-Scale Fresnel Optical Lens Manufacturing
In the realm of optical component manufacturing, producing large-diameter (up to 1 meter) Fresnel lenses presents a formidable challenge. These lenses are indispensable in cutting-edge applications such as solar concentration, large-scale projection displays, and astronomical observations. Leveraging its exceptional technical expertise, advanced equipment, and specialized team, Yighen Ultra Precision excels in the fabrication of these complex lenses. We can manufacture Fresnel lenses with diameters up to 1 meter and have the capability for mass production using UV imprinting and hot pressing techniques, meeting the stringent demands of high-end applications.
Advanced Equipment Ensures Precision
At the heart of our precision lies an array of state-of-the-art machinery:
The NanoTech 650 FG ultra-precision freeform machining center, one of Yighen's core processing tools, employs advanced slow tool servo (rotary) and fly-cutting technologies to handle intricate surface geometries. For large Fresnel lenses, this machine precisely controls the tool paths and cutting depths, achieving form accuracy (PV) of 0.15 microns and surface roughness (Ra) as low as 3.0 nanometers on a 1-meter diameter lens. With programming resolutions reaching 0.01 nanometers linearly and 0.0000001 degrees angularly, it ensures every detail meets high-precision optical standards.
Additionally, we utilize Toshiba single-point diamond turning lathes ULC-100D(S) and ULC-100F(S), which play critical roles in high-precision optical component manufacturing. The ULC-100D(S) offers X and Z axis resolutions of 0.000001mm and C axis resolution of 0.0000mm, achieving PV of 0.015um and Ra of 0.002um during mold insert machining. The four ULC-100F(S) machines feature even finer resolutions of 0.0000001mm in X and Z axes, delivering PV of 0.010um and Ra of 0.001um. Equipped with high-precision, high-rigidity V-V rolling guide surfaces and ultra-precise air spindle bearings, they ensure precise material removal for optimal optical performance.
For grinding processes, Toshiba ultra-precision grinding machines ULG-100D HYBS3 and ULG-100D(H3) offer significant advantages. These machines achieve ultra-fine finishes with Pv values down to 0.030um and Ra of 0.01um, enhancing the flatness and smoothness of large Fresnel lens surfaces.
The Toshiba nano-processing center UVM-450D(H) serves as an ultra-precision vertical machining center, providing fast feed rates and broad spindle speed ranges. It achieves resolutions of 0.00001mm in X and V axes and 0.0000mm in the Z axis, ensuring efficient and precise handling of complex structures like fine edges on large Fresnel lenses.
Comprehensive Inspection Capabilities
Our inspection suite includes devices like the Panasonic ultra-high precision 3D measuring instruments UA3P-300 and UA3P-400T, capable of highly accurate profile measurements and dimensional checks with resolutions of 0.000001mm across all axes. This ensures any deviations affecting optical performance are promptly identified and corrected.
The Zygo non-contact interferometer utilizes light interference principles to measure surface roughness with a Z-axis resolution of 0.00000001mm, providing crucial data for optimizing the manufacturing process and ensuring adherence to optical standards.
The All-European optical eccentricity measurement device focuses on detecting optical eccentricity with sub-micron precision, essential for maintaining concentricity in multi-element lenses and improving imaging quality by reducing aberrations.
Finally, the Nikon image-based three-dimensional measuring machine combines advanced optical imaging technology with precise mechanical motion systems, offering comprehensive size, shape, position tolerance evaluation, and surface defect detection with resolutions of 0.0001mm across all axes.
Expert Team Drives Innovation
Our team comprises elite professionals from leading academic institutions worldwide, specializing in optics design, ultra-precision machining, and materials science. Graduates from Nanyang Technological University, University of Strasbourg, CIOMP under the Chinese Academy of Sciences, and Zhejiang University bring deep theoretical knowledge and practical experience to address complex challenges in large Fresnel lens manufacturing.
Our optical design experts use advanced software to tailor Fresnel lenses for specific applications, optimizing parameters such as curvature, groove spacing, and depth for optimal performance. In process development, our team continuously refines manufacturing techniques, addressing issues like material deformation and cutting stress through innovative methods like optimized cutting parameters and real-time stress monitoring.
Robust Investment Fuels Growth
Backed by renowned investors including Innoangel, Houtian Capital (Xiaomi Ecosystem), WeiYi Capital, Jiangguan Capital, and Future Black Technology, Yighen has secured substantial funding for technological research, equipment upgrades, and team expansion. This investment enables us to continually introduce leading-edge processing and inspection equipment, invest in R&D, and tackle technical challenges in large Fresnel lens manufacturing, solidifying our competitive edge and leadership in the industry.
With a commitment to excellence, Yighen Ultra Precision is poised to deliver superior large-scale Fresnel lenses and services, advancing the frontiers of optical technology.
