Volume 9, Number 2 March/April 2001

Transcription

1 Volume 9, Number 2 March/April 2001 QED Technologies takes Precision Finishing into the Next Dimension! Michele L. Stolberg, Harvey M. Pollicove - Center for Optics Manufacturing QED Technologies Inc. introduced their latest generation of magnetorheological finishing (MRF) equipment technology, the Q22-Y MRF System, at Photonics West 2001 (San Jose, CA) in January. The Q22-Y MRF System expands on the success of the Q22-X MRF System. The Q22-X was specifically designed to use a spiral toolpath optimized for rotationally symmetric spheres, flats and aspheres. The Q22-Y extends this capability by providing industry users with a system to polish square or rectangular optics, such as mirrors, windows, prisms, and cylinders, to less than 10 angstroms rms surface microroughness and better than 0.05 wave p-v surface form. The Q22-Y utilizes a raster toolpath approach to polishing that expands the ability of MRF past spherical lenses to square and rectangular aperture optics. These enhanced capabilities include figure and angle correction for prisms, final figuring of photoblank substrates, and figure correction of cylindrical optics. The underlying MRF technology remains the same, utilizing a special fluid and a magnetic field to finish optical surfaces with no subsurface damage. The MR fluid is a suspension of magnetic particles and polishing abrasives whose shape and stiffness can be controlled and manipulated in real time to create a compliant polishing spot that is capable of polishing and correcting any optical surface. The polishing spot replaces the specialized rigid laps used in conventional non-deterministic polishing processes. One of the most important innovations in this Figure 1: Q22-Y MRF System. most recent advance of QED s MR finishing technology is the Q22-Y s ability to regulate process variables such as fluid viscosity, magnetic field intensity, and raster sweep rate of the lens through the fluid. These variables can be directed to correct both symmetric and non-rotationally symmetric (i.e. astigmatism) surface form errors. These errors are typically introduced in previous manufacturing steps, and are very difficult to correct using conventional polishing methods. continued on page 2 Inside: OSLO... 3 APOMA... 3 Job Postings... 4 Summer School... 5 Industry Calendar... 6 Copyright University of Rochester CENTER FO R OPTICS MANUFAC TURING 1

2 continued from page 1 The five axis Q22-Y raster toolpath (pictured below) enables the MR polishing spot to cycle from left to right and return, eliminating damage and correcting figure on a mirror or window. Figure 2: Q22-Y Raster Toolpath. Figure 3: Thin Plano Lens Polished on the Q22-Y. The Q22-Y uses this raster toolpath to polish the plano faces of square, rectangular, or any odd-shaped workpieces. This unique approach enables polishing and figure correction of prism surfaces all the way out to the corners and the thin knife-edges. Trying to conventionally polish prism faces to uniformly high precision is extremely challenging, particularly at the outer edges where polishing into the corners presents the highest degree of difficulty. The Q22-Y can polish prism faces to within 1.0 mm of their physical edge to better than 0.04 wave p-v. There is no other commercially available technology capable of completing this difficult task. MRF s insensitivity to mounting distortion or deformation during polishing makes it the logical choice for thin windows and mirrors. As long as the lens metrology is performed with the optic in a stress-free condition, the Q22-Y controller will instruct the system to remove only the interferometrically designated amounts of material from their proper locations. This feature removes the risks of erroneously polishing the surface of a lens that has become distorted during mounting. The optic is supported with a vacuum chuck during polishing, enabling the Q22-Y to figure correct surface or thickness error. The Q22-Y MRF System is capable of figuring 200 mm diameter plano, spherical, aspherical, and cylindrical optics with round or non-round apertures to better than 0.05 wave p-v in minutes, a revolutionary advance in optics manufacturing. Prior to the invention of MRF, aspherical and freeform optics had been so expensive, or impossible, to produce that they had been precluded from general use. By combining specialized MR fluids, multi-axis CNC equipment, and computer algorithms written for a raster approach to polishing, the Q22- Y achieves high removal rates and short cycle times that produce precisely polished surfaces in minutes instead of weeks. Figure 4: Figure Correction Results with Conformal Rastering. continued on page 4 2

3 OSLO Training Courses Offered Rochester, New York Optical Design Using OSLO April 30-May 1, 2001 Presented by Leo Gardner, Lambda Research Corporation Using OSLO is an introductory course for new or current users who want to use OSLO more effectively. Emphasis is placed on new features and ways to improve your productivity in optical design. CCL Programming for Optical Design May 2, 2001 Presented by Doug Sinclair, Sinclair Optics, Inc. The scope of optical design has increased dramatically during the past few years, new application areas in communications, illumination systems, and micro-optics require special analyses and flexibility. OSLO provides solutions through its CCL language, a modern byte-code language tailored specifically to engineering applications. This course shows how to use it effectively in optical design. Design of Consumer Optics May 3-4, 2001 Presented by Ellis Betensky, Optical Design Consultant As optics becomes a mainstream consumer technology, high volume production and new imaging requirements create a need for entirely new imaging systems. This course shows you how to design consumer optics. Prerequisites: Optical Design Using OSLO course; basic first-order optics. The OSLO spring training courses will be held in the upstairs seminar room at the University of Rochester, Center for Optics Manufacturing, 240 East River Road, Rochester NY. Tuition fees include all materials, shared use of computers, continental breakfast, and box lunches. Tuition must be paid in full prior to attendance. Space is limited due to the laboratory nature of the courses. To register, please contact Sinclair Optics, Inc., 6780 Palmyra Road, Fairport, NY (phone , fax , course@sinopt.com). Additional information is available at: APOMA Elects New Board Members The APOMA membership recently elected four new Board Members to the nine member Board of Directors. Richard Nasca, Optical Manufacturing Manager for Tropel Corporation, becomes President-Elect. Arnie Bazensky, Western Regional Sales Manager for Schott Glass Technologies Inc., assumes the Corporate member director role. James Sydor, President of Stefan Sydor Optical, is also a Corporate member director and John Nemechek, Sales Manager for Fisba Optik, is the Associate member director. Hal Johnson, President of Harold Johnson Optical Laboratory, assumes the role of APOMA President. All newly elected APOMA Board Members will serve for a period of two years. Visit the APOMA website: Laser Power Corporation Briggs Road Murrieta, CA Rep: Todd Sanders Phone: Fax: Liebmann Optical Co., Inc. 1 Industrial Parkway Easthampton, MA Rep: Glenn Gilbert Phone: Fax: Lightwave Enterprises Inc. 150 Lucius Gordon Drive Suite 100 Henrietta, NY Rep: Steve Arnold Phone: Fax:

4 ...JOB POSTINGS...JOB POSTINGS...JOB POSTINGS... COMPANY: Reflexite PTC 1300 Mt. Read Blvd. Rochester, NY Attn: Shelley Willison Fax: Title: Diamond Turning Machinist/Technician Description: Experienced diamond turning machinist/ technician responsible for running multiple diamond turning machines and turning various materials to support on-going manufacturing and current R&D/prototyping efforts. Experience: 3-5 years experience in manufacturing optical tooling on large and small DPT machines. Must be experienced in fabrication of flat, spherical and aspheric surfaces on CNC equipment and have precision machining experience to sub-micron tolerances. Experience in diamond turning of fresnel lenses is desirable. Technical trade school, toolmaker, and/or apprenticeship preferred. Please send resumes to address above. The new Center for Optics Manufacturing brochure and video (available on CD or VHS) is now available! To request a copy, please contact Kelly Grover (phone , kgro@lle.rochester.edu). COMPANY: Zygo Corporation Laurel Brook Road Middlefield, CT Attn: Human Resources Recruiter Fax: jobs@zygo.com The following opportunities are currently available. Please see our website ( for job descriptions. Unless otherwise noted below, all positions are located at our Middlefield, CT headquarters. Field Service Engineer Coating Technicians Coating Engineer Opticians (Grinders, Polishers) Software Engineer Optical Engineers Opto-Mechanical Engineers Opto-Mechanical Applications Engineer Systems Engineers Account Manager (Indiana/Michigan) Metrologist, Testing Services Zygo offers a work environment that supports important corporate values such as integrity, excellence, respect, and teamwork. Zygo offers competitive salaries and benefits, including stock options/profit sharing. Please forward or your resume and salary requirements to the address above. continued from page 2 P-V: µm RMS: µm ~ 7 minutes Polishing time Figure 5: High Aspect Ratio Flats Polished on the Q22-Y. P-V: µm RMS: µm 4 For more information on the Q22-Y MRF System, please contact QED Technologies Inc. at or via at sales@qedmrf.com (website:

5 New Machines, Tools and Processes for Modern Optics Manufacturing (with Labs) COM's annual summer school, "New Machines, Tools and Processes for Modern Optics Manufacturing," will be offered from June 25-28, 2001 in Rochester, New York. The course is organized into 21 talks and tutorials providing an overview of emerging technologies that will shape the way optics are manufactured into the next century. Guest speakers join the Center for Optics Manufacturing/University of Rochester professors and engineers to present the most recent manufacturing technology advances in deterministic processing and flexible automation for producing spherical, aspheric, and conformal optics. The program is very interactive, providing two full afternoons of laboratory work on computer integrated manufacturing of aspheres, programming a CNC machine for complex shapes, on-machine probes, magnetorheological finishing, and modern optics metrology. The cost for the 4 day course is $1,000; more information may be obtained by contacting Gayle Thompson at the Institute of Optics (phone , fax , GAYLE@OPTICS.ROCHESTER.EDU). AGENDA Monday, June 25 COM Introduction and Next Generation Optics Issues Harvey Pollicove (UR/COM) Deterministic Grinding of Spheres, Aspheres, and Conformal Parts Jeff Ruckman (UR/COM) Chemical Effects in Classical Optics Fabrication Mike Cumbo (OCLI) Survey of Commercial Systems for Optics Manufacturing from One Arne Lindquist (Schneider) Manufacturer s Perspective Glass, glass making and properties Joseph Hayden (Schott Glass Tech.) The Optics Suitcase Demos to Recruit Students into Optical Steve Jacobs (UR/COM) Engineering Careers COM Reception/Open House (sponsored by Schneider Optical Machinery) Tuesday, June 26 What Mechanics and Materials Science Can Do for Optics Mfg. How Diamond Tools Work Glass Vibration Analysis of CNC Machines for Optics Manufacturing CNC Generating Lab Materials Science/Classical Optics Fabrication Lab Wednesday, June 27 Precision Optics Manufacturing for the Future Using MRF Interferometric Form Metrology for Precision Machined Surfaces Single-point Diamond Turning (SPDT) Modern Optics Metrology Lab Magnetorheological Finishing (MRF) Lab Open House at QED Technologies Thursday, June 28 Where Do Optical Tolerances Come From? Optical Polishing Pitch and Pitch Laps Diffractive- and Micro-optics Fabrication and Applications Manufacture of Precision Polymer Optics John Lambropoulos (UR/ME) Paul Funkenbusch (UR/ME) Sheryl Gracewski (UR/ME) Donald Golini (QED Technologies) Andrew Kulawiec (Tropel) John Schaefer (Raytheon Elcan Texas) Maria Robinson (Zygo Corp.) Julie Bentley (Tropel) Birgit Gillman (Zygo Corp.) G. Michael Morris (Corning/RPC) Mark Madigan (OCLI) 5

6 2001 INDUSTRY EVENTS Representatives from COM will be attending the following optics industry events. Stop and see us at: SPIE s OPTO Northeast & Imaging 2001, Rochester, NY April 10-11, 2001 AeroSense 2001, Orlando, FL April 17-19, 2001 CLEO 2001, Baltimore, MD May 8-10, 2001 SPIE Annual Meeting, San Diego, CA July 31- August 2, 2001 NEWSLETTER MAILING LIST UPDATE Please let us know of any address corrections, additions, or deletions by completing this form. Mail or fax to Michele Stolberg at the Center, fax Name: Title: Company: Address: City, State, Zip: Phone: Fax: 6 CENTER FOR OPTICS MANUFACTURING University of Rochester 240 East River Road Rochester, NY Stop by and visit COM s NEW web address!