Diamond Turning
Single Point Diamond Turning (SPDT) plays a key role in nearly all of our polymer optics programs. Whether it’s prototyping, tooling inserts, pilot production, or some combination of the three, diamond turning is a fundamental part of our process.
Prototyping
We work with you to come up with the very best solutions for your challenges!
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Can it be made?
Optical engineers are constantly challenging us with increasingly difficult designs that push the limits of manufacturability.
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How will it perform in the system?
Rapid prototyping by diamond turning a few optical elements allows engineers to test their optical designs in their systems before heavy investments in tooling capital. Often times, this pays off!
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Feasibility for polymer in the system?
Not sure if a polymer optic will perform as well as glass in your system? Give it a try first and know for sure (usually it does just fine).
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Diamond turning for molding.
For prototyping, we use precision diamond turning to replicate the tolerances of our injection molding process. This approach ensures that our prototypes accurately reflect the final molded optics, enabling engineers to verify the exactness of optical systems before full-scale production.
Injection Mold Inserts
New Optical Mold Inserts
We diamond turn our optical mold surfaces in-house to ensure full control of form, surface roughness, and mechanical dimensions.
New or Transfer Mold Insert Error Compensation
Optical surfaces are first diamond turned to the nominal prescription and injection molding trials begin. However, polymer doesn’t always follow the rules and shrink uniformly – especially with free form surfaces. In this case, we perform advanced form metrology, feed that data into our diamond turning machine, and then re-cut the mold inserts to compensate for the inherent error in the molding process. After post-mold shrink and stabilization, the result is a molded optic that meets prescription specifications for form – spot on.
Optical Insert Maintenance
We have the equipment onsite to perform 100% cleanup cut to breathe new life into old optical inserts and extend the longevity of molds transferred to Diverse Optics.
Pilot Production
- Bridge the gap between injection mold build time and immediate market demand
- Test market acceptance prior to investment in tooling
- When specifications are just too tight for injection molding
- 13 Diamond Turning machines
- 5-Axis diamond turning and milling for complex geometries
- 80,000 RPM Levicron diamond milling spindle
- Fast-Tool-Servo (FTS) with 5mm travel
- Son-X ultrasonic diamond turning for 55 HRC stainless steel tool inserts
Interested in Diamond Turning?
Speak to an Expert Today!
We want to know your needs exactly so that we can provide the perfect solution. Let us know what you want and we’ll do our best to help.