We report on the latest developments in fast tool servo technology for cutting freeform surfaces and lenslet arrays. Fast tool servo cutting performance is examined and contrasted to micro-milling and XZC turning for low spatial frequency surfaces and high spatial frequency surfaces (e.g. lens arrays). The influences of servo bandwidth, positioning resolution, and vibration level are examined in terms of their effect on form accuracy, mid-spatial frequency errors, surface finish and cutting time.
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