Multi-Side Optical Component Fabrication via Reference Surface Alignment
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Solution Overview
Problem
Current methods are inadequate for producing optical components with at least three non-rotationally symmetrical optical functional surfaces monolithically arranged on two different sides of a common base body with high precision and minimal effort.
Innovation Solution
A method involving the calculation and production of a continuous surface composite for optical functional surfaces on one side, with repositioning and processing of additional surfaces on the opposite side using reference surfaces to achieve precise alignment and correction, employing micro-cutting techniques like ultra-precision diamond processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If optical functional surfaces are produced on multiple sides of a base body using conventional methods, then the number of surfaces can be increased, but the manufacturing precision and alignment accuracy deteriorate due to multiple setup operations
Solution Approach 1:
Reference surfaces are produced in advance during the first setup operation before the component is repositioned. These pre-produced reference surfaces serve as accurate alignment features for subsequent operations, eliminating the need for complex re-alignment procedures and ensuring high precision across multiple optical surfaces produced in different setups.
2Adaptability or versatility
If multiple optical functional surfaces are produced on different sides of the base body, then the functionality of the optical component is enhanced, but the manufacturing time and processing effort increase due to repositioning operations
Solution Approach 1:
The method employs measurement and correction steps where the actual positions and orientations of produced optical surfaces are measured, and correction values are calculated and applied in subsequent operations. This feedback mechanism ensures that even after repositioning operations, the final alignment accuracy meets requirements, minimizing the need for excessive rework and reducing overall manufacturing time.
3Device complexity
If conventional machining methods are used for multiple optical surfaces, then the device complexity is reduced, but the difficulty of achieving high precision alignment increases
Solution Approach 1:
Reference surfaces act as intermediary features that facilitate precise alignment between the base body and subsequent optical surfaces. These reference surfaces provide stable, measurable features that mediate the alignment process, making it easier to achieve high precision without requiring complex direct measurement and alignment procedures for each optical surface.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a method for producing an optical component (1) having at least three monolithically arranged optical functional surfaces (7, 8, 9, 10) on two different sides of an optical component (1), comprising the steps of calculating a continuous surface composite (22) having at least two optical functional surfaces (7, 9), producing the continuous surface composite (22), the production of at least one reference surface (1), repositioning the optical component (1), wherein the at least one reference surface (1) serves as an assembly surface, producing at least one further optical functional surface (8, 10) on the second side of the optical component (1), measuring the shape and position of the optical functional surfaces (7, 8, 9, 10), and repeating the steps of processing the first and second optical functional surfaces (7, 9), repositioning the optical component (1) and processing the at least one further optical functional surface (8, 10) for corrective processing of the optical functional surfaces (7, 8, 9, 10).