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OptoTech
Smart Solutions for Professionals
Multi Tool Concept
Matthias Pfaff, Roland Mandler, Sebastian Stoebenau
OptoTech Optikmaschinen GmbH
APOMA Fall Workshop 2016
Tucson, AZ, USA
2016-11-10/11
OptoTech
Smart Solutions for Professionals
Content
• Introduction OptoTech
• Motivation
• Grinding Technology
• Multi Tool Polishing Technology
– Membrane Polishing FEM-Tool
– Advanced Wheel Polishing Technology A-WPT
– Active Fluid Jet Polishing A-FJP
– Sub-Aperture Pitch Polishing
– Pitch Polishing
– SynchroSpeed Polishing
OptoTech
Smart Solutions for Professionals
OptoTech
• Found 1985 by Roland Mandler
• 250 employees at 8 sites worldwide
• Equipment for precision optics (60%),
ophthalmics (30%) and coating (10%)
• Export ratio of >85%
OptoTech
Smart Solutions for Professionals
OptoTech (2)
Precision Optics Ophthalmics
Coating Tooling Consumables
Metrology
OptoTech
Smart Solutions for Professionals
Worldwide Presence:
Wettenberg
Milan (Italy)
Jena
Palm, PA
(USA) •
Bellach
(Switzerland)
Mumbai
(India) Hong Kong
•
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•
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• OptoTech Subsidiaries • Sales- and Service-Agencies
OptoTech (3)
Germantown, WI
(USA)
OptoTech
Smart Solutions for Professionals
Motivation
• Big mix of geometries, machine
kinematics and tools used in prior
processing steps (grinding, pre-
polishing)
• They all have an influence on the
following polishing and correction
technologies.
• There is no “one tool fits all”, especially
on asphere and free form processing
OptoTech
Smart Solutions for Professionals
Spherical Grinding Technology
• Spherical Grinding
– Cup wheels
– Circular tool contact
– Smoothing effect of line contact
– Improved by 3C Technology
OptoTech
Smart Solutions for Professionals
Aspherical Grinding Technology
• Aspherical and Free
Form Grinding
– Peripheral wheels
– Single point contact
– One time touch of tool
and workpiece
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OptoTech
Smart Solutions for Professionals
Consequence
• Every geometry and every error type
requires different handling on the
follow-up process
• Ergo: we do require various
polishing concepts with a high
freedom of tooling and machine
kinematics
• OptoTech MultiTool Concept
OptoTech
Smart Solutions for Professionals
MultiTool
• Spherical and Plano Surfaces
– SynchroSpeed Polishing
– Pitch Polishing
• Aspherical and FreeForm Surfaces
– FEM Membrane Polishing
– A-WPT Advanced Wheel Polishing Technology
– A-FJP Active Fluid Jet Polishing
• Fine Correction and Smoothing
– As above, plus
– Sub Aperture Pitch Polishing
OptoTech
Smart Solutions for Professionals
SynchroSpeed® Polishing
• Development of abrasion-optimised
tools
– Kinematics
– Machines concepts
• Basics
– Since 1965: Erhard Brück (Leitz, Wetzlar)
– Since 1974: Erhard Brück (Loh, Wetzlar)
• Improvements and optimisations
– Since 1985: Roland Mandler (OptoTech)
OptoTech
Smart Solutions for Professionals
SynchroSpeed in a nutshell
• Projection of the glass
surface into the tool
• Considering relative
speed and radius
• rlens = rtool = const
• r(t) = 0
• Radius ≠ f(t)
• C/T = f(t) .cos
2
1 constn
nrel
OptoTech
Smart Solutions for Professionals
SynchroSpeed and Pitch Polishing
• SynchroSpeed Polishing
– Fast and relatively inexpensive tool set
– Very flexible and well suited for small
batches
– Surface roughness higher than pitch
• Pitch Polishing
– Very slow and expensive tool set (incl.
auxiliaries)
– Not flexible at all
– Excellent surface roughness
OptoTech
Smart Solutions for Professionals
Polishing of plano optics and spheres using large-area tools:
SynchroSpeed technology
Established process with high removal rates and low-frequency residuals
SynchroSpeed Polishing
OptoTech
Smart Solutions for Professionals
Improved correction convergence using POLyCAM 3D by a user-
defined active polishing spot diameter that is automatically kept
constant across the surface!
Processed sample: asphere Ø 50 mm, PV < 0,2 µm within 80 min
Polishing of plano optics, spheres and aspheres using sub-aperture tools:
Membrane Tool Technology
FEM Membrane Polishing Tool
OptoTech
Smart Solutions for Professionals
Polishing of plano optics, spheres and aspheres using sub-aperture tools:
OptoTech patented technology: A-WPT (Advanced Wheel Polishing Tool)
Optimized kinematics by introducing an additional
axis of rotation
Improved surface quality combined with highest removal rates!
conventional wheel polishing
= directional structures
A-WPT
= isotropic surface texture
A-WPT Advanced Wheel Polishing
Technology
OptoTech
Smart Solutions for Professionals
A-FJP Corrective Polishing
- polishing pin pressed to surface by polishing slurry
- eccentrically rotating movement along raster or spiral path
- highly deterministic correction of low-spatial frequencies
- excellent surface quality depending on tool-type
Polishing felt on rubber pin
Ra = 1,39 nm (Rq = 1,74 nm)
Pitch on PU foil on rubber pin
Ra = 0,29 nm (Rq = 0,38 nm)
A-FJP Active Fluid Jet Polishing
OptoTech
Smart Solutions for Professionals
Micro-roughness achieved
Ra = 0.33 nm (RRMS = 0.42 nm)
Pitch Polishing with Sub-Aperture Tools
- small – partly elastic – form tool
- excellent smoothing of MSF’s
- excellent surface quality
Sub-Aperture Pitch Polishing
OptoTech
Smart Solutions for Professionals
Machine Platform
• Technologies introduced in this paper
do require a machine platform with
maximum freedom regarding versatility
and machine kinematics
• OptoTech MCP series (Machine
Centre for Polishing)
• @ TCT: MCP 250 CNC
OptoTech
Smart Solutions for Professionals
Polishing Technologies:
SynchroSpeed Polishing A-WPT Polishing
Active-Fluid Jet Polishing Sub Aperture Pitch Polishing
Membrane Polishing Standard Pitch Polishing
• 6-Axis Polishing Machines of the MCP Series (Multi-Centre-Polishing)
MCP 251 CNC MCP 501 CNC MCP 1001 CNC MCP 1501 CNC
MCP Machine Series with MultiTool Technology
OptoTech
Smart Solutions for Professionals
Conclusion
• Different combinations of geometries,
previous processes, error characteristics
require different approach on polishing and
fine correction technologies
• Specialisation requires different machines
for a single task
• Generalisation enables one machine for
different tasks: MultiTool Concept
OptoTech
Smart Solutions for Professionals
Acknowledgements
• Erhard Brück: SynchroSpeed Polishing
• Roland Mandler: Advanced
SynchroSpeed Polishing
• Sebastian Stoebenau: Process
Development MultiTool
OptoTech
Smart Solutions for Professionals
Questions?
Matthias Pfaff
T: +49 641 98203 819
W: www.optotech.de
OptoTech
Smart Solutions for Professionals
OptoTech
Smart Solutions for Professionals
Thank you
For your attention!
www.optotech.de
OptoTech
