Mastering the Challenge of Non-Rotational Symmetry in Fresnel Lens Manufacturing
In the field of optical engineering, non-rotational symmetry Fresnel lenses—such as linear and elliptical Fresnel lenses—are increasingly vital components in cutting-edge applications like solar concentration, laser beam shaping, and machine vision. Their unique optical properties enable advanced light control, but their complex surface structures and demanding precision requirements have long posed a major challenge for traditional manufacturing methods. At Yighen Ultra Precision, we have successfully overcome these challenges through technological innovation, offering high-precision solutions that redefine what’s possible in non-symmetrical optical design.
The Complexity of Non-Rotational Symmetry
Unlike conventional rotationally symmetric lenses, non-rotational Fresnel lenses feature surfaces with continuously varying curvature, groove spacing, and depth—without fixed patterns or symmetry. This structural complexity places extreme demands on machining accuracy, toolpath planning, and process stability. Traditional equipment often struggles to precisely follow such intricate geometries, leading to contour deviations, surface imperfections, and ultimately compromised optical performance. Furthermore, the microstructures on these lenses are typically measured in microns or even nanometers, where the smallest error can significantly affect light behavior. Repeated setups and multi-step processes also introduce cumulative errors, making consistent, high-quality mass production particularly difficult.
Yighen's Technological Breakthroughs
To address these challenges, Yighen has developed an integrated approach combining hardware upgrades, intelligent software, and advanced composite processing techniques.
Upgraded Equipment for Precision Machining
At the core of our solution is a fleet of upgraded ultra-precision single-point diamond turning machines equipped with high-accuracy five-axis联动 systems. These systems allow tools to move flexibly across five dimensions, precisely following the complex contours of non-symmetrical surfaces. Enhanced motion control algorithms and high-resolution feedback sensors ensure positioning accuracy down to the nanometer level, minimizing deviation during machining. This advanced hardware provides the foundation for consistently achieving sub-micron form accuracy and surface roughness below 10nm.
Intelligent Toolpath Planning Algorithms
To further enhance efficiency and precision, Yighen has developed proprietary intelligent toolpath planning algorithms based on advanced computational geometry and optimization theory. These algorithms analyze 3D lens models and generate optimized cutting paths that minimize tool interference, reduce idle movement, and maintain optimal cutting conditions throughout the process. For example, when machining linear Fresnel lenses, the algorithm adapts dynamically to stripe distribution, ensuring uniformity in groove depth and spacing within extremely tight tolerances—crucial for high-performance optical systems.
Composite Processing for Superior Surface Quality
Beyond diamond turning, Yighen applies hybrid processing technologies such as magnetorheological finishing and ion beam figuring to refine surface quality. Magnetorheological finishing uses magnetic fields to precisely control polishing fluid flow, effectively removing microscopic defects and reducing surface roughness. Ion beam figuring enables atomic-level material removal, allowing fine adjustments to surface form and achieving sub-micron form accuracy. Together, these techniques ensure that every lens meets the most stringent optical specifications.
Real-World Applications Across Industries
The high-precision non-rotational Fresnel lenses produced by Yighen are already driving innovation across multiple sectors. In machine vision, they enhance imaging clarity and resolution, enabling more accurate industrial inspection and AI-based recognition systems. In medical devices, they support advanced diagnostic tools with superior optical fidelity. In scientific research, they fulfill the demand for custom optics in high-end experiments, pushing forward the frontiers of optical science.
Built on Expertise and Innovation
Behind Yighen’s success lies a team of world-class experts from top global institutions, including Nanyang Technological University, the University of Strasbourg, CIOMP (Changchun Institute of Optics), and Zhejiang University. With deep expertise in optical design, ultra-precision machining, materials science, and automation, this team continues to push the boundaries of what’s possible in optical manufacturing.
Complementing this talent base is Yighen’s comprehensive R&D and testing infrastructure. Advanced simulation tools like CAD/CAE software help optimize designs and machining parameters before production begins, shortening development cycles and reducing costs. High-precision instruments—including laser interferometers, atomic force microscopes, and SEMs—ensure rigorous quality control at every stage, guaranteeing that every product meets exacting standards.
Recognition and Vision for the Future
Yighen’s innovations in non-rotational symmetry Fresnel technology have earned widespread industry recognition, including multiple national and provincial awards for scientific and technological advancement, along with several granted national invention patents. These accolades reflect both our past achievements and our ongoing commitment to progress.
Looking ahead, Yighen will continue to invest in R&D, refining current techniques and exploring new materials and processes. Our goal is to deliver ever-higher precision, greater efficiency, and lower costs—empowering customers with next-generation optical solutions and driving the evolution of optical manufacturing into uncharted territory.
