Diamond turning is the process of creating ultra-precision parts for various applications that need a high level of accuracy and reflective parts. In other words, it’s a machining process that removes material from a workpiece using a CNC lathe.
Diamond turning is a distinctive turning process that uses a diamond-tipped cutting tool. Most diamond turning operations use a single-point cutting tool known as single-point diamond turning (SPDT). However, diamond turning also takes place using a multiple-point cutting tool.
What are the Benefits of Diamond Turning?
- Diamond turning process produces very high-quality parts with high-level precision. It means that the product has a smooth surface and a mirror finish ultra-precision parts
- Produces great diamond-turning optic surfaces
- Easily transforms soft, malleable material that is hard to polish
- Speed of delivery
- Reduces tooling costs
Which are the Diamond Turning Methods?
Over time, there are several approaches to machining that evolve. At the center of each is the accuracy of the diamond turning machine. It can position a tool with an uncertainty of more than 100 nanometers. These basic approaches include;
- Traditional turning– It’s a turbocharged version of classic lathe work. The CNC interposition of the X and Z axis of the machine produces random rotational symmetric parts. In other words, it’s very easy to produce the parabola of a telescope as it is to produce a simple cylindrical shape.
- Off-axis turning– It’s an approach where a workpiece is attached to the spindle in an asymmetric style. It allows the cutting of multiple parts simultaneously, producing contours whose rotational center doesn’t coincide with the center of the part. Helps in the generation of certain optical configurations.
- Fly-cutting- It reverses the position of work and tool. The work is attached to the slide with the tool attached to the spindle. It allows the generation of elliptical surfaces.
- Free-form machining– when adding more motions to the machine, you will create a free-from surface with no rotational axis. High-speed grinding spindles replace the single-point tool. You can easily machine ceramics and glass like metals and crystals cut with single-point diamond turning.
What are Diamond Turning Materials?
Different polymers can be diamond-turned directly. These include
- Acrylic (PMMA)
- Polyester(OKP-4)
- COC(Topas)
- Polyetherimide
- COP(Zeonex and Zeonor)
- Sytrene
- Other select polymers.
However, some plastics, such as polycarbonate, aren’t suitable since they are too soft. Therefore, you must choose a suitable material at the onset of your project. It will ultimately affect your end product. Finding the right material ensures the creation of an amazing end product.
What’s the Usage of Diamond Turning in the Optical Industry?
A large fraction of the diamond turning process is for producing optical materials. Its popularity in the optical industry is due to its capability to produce highly accurate and refined surface profiles. Additionally, it’s becoming more popular in biomedical applications, especially contact lenses mass production. Production of the contact lens is affordable but highly accurate.
Diamond turning is very effective when used in manufacturing infrared optics. The process gives a smooth surface finish that’s not possible from other machining processes. In addition, diamonds are known as the world’s hardest materials, making them useful in different machining processes.
Three single point diamond turning lathes are now available from Apollo Optical Systems: two Precitech Optimum 2400 two axis lathes and one Precitech Nanoform 200 three axis lathe (for manufacturing asymmetrical components).
Three single point diamond turning lathes are now available from Apollo Optical Systems: two Precitech Optimum 2400 two axis lathes and one Precitech Nanoform 200 three axis lathe (for manufacturing asymmetrical components).
- Custom, exclusive diamond tools from AOS have radii as small as 1.5 micron.
- AOS manufactures optical parts with diameters ranging from 1 mm to 300 mm.
- AOS has produced finishes in all materials that are superior to the norm. As an illustration, AOS achieved a surface polish of 13 RMS in nickel for one customer and 31 RMS in polystyrene for another.
In most polymers, AOS typically achieves a surface polish of 60–80 RMS and a peak–to–valley surface figure of 1/2. In terms of metal surfaces, Apollo Optical regularly achieves 30 to 50 RMS surface polish and 14 wave peak-to-valley surface figure.
Single Point Diamond Turning: Top-notch craftsmanship from start to finish
Quality is our top priority at all times, from the outset of our conversations with customers through the point of delivery. The most recent AOS metrology is used to support our Single Point Diamond Turning centre. We can fully characterise all of our SPDT optical components and moulding inserts thanks to our in-depth expertise and experience in optical design and metrology.
AOS has an extensive in-house design and testing infrastructure to support its Single Point Diamond Turning services. Support capabilities include:
Optical Engineering
Single Point Diamond Turning: Top-notch craftsmanship from start to finish. The SPDT tool path is produced by Surface Modeling Lens Design AOS using proprietary software in conjunction with commercial mechanical design software.
AOS is vertically integrated with in-house operations for optical and mechanical engineering, SPDT, optical moulding, metrology, and testing.
