OptiPro Systems, LLC has been recognized as a U.S. leader in computer-controlled equipment for manufacturing high precision optical components found in medical, military, aerospace, night vision and many other industrial and commercial applications. OptiPro’s success in winning several Small Business Innovative Research (SBIR) grants through the Navy, NASA and the Army have led to the commercialization of new machines, software and processes for grinding, polishing and measuring complex optics such as windows and domes. OptiSonic machines incorporate the latest in ultrasonic machining technology by adding 20-40 kHz of adaptive oscillation to the grinding tool, which reduces force on the tool and part during processing. OptiSonic machines have proven to increase processing speed and precision when grinding various hard optical materials that are ideal for hypersonic applications. UltraForm Finishing (UFF) machines are capable of deterministically finishing windows, domes, and other complex optical elements through a patented sub-aperture polishing technique. This method involves a moving belt of polishing material wrapped around a precision compressive wheel. UltraSurf machines deliver ultra-precision non-contact metrology though the utilization of high-quality machine components and the latest non-contact probe technologies. The measuring probe is scanned over the optical surface while maintaining perpendicularity and a constant focal offset. Finally, our PROSurf freeform computer-aided manufacturing (CAM) software is used to develop advanced toolpaths for each of these platforms. We will present an overview of each of these technologies and discuss how they are advancing the precision optics manufacturing world.
UltraForm Finishing (UFF), OptiPro Systems' five axis sub-aperture polishing machine has evolved from an initial
prototype into a robust aspheric manufacturing system that can rapidly produce finished aspheres directly from a ground
surface. UFF utilizes a belt of polishing material 50" long supported by a polyurethane wheel to polish a wide variety of
materials ranging from traditional glasses to IR materials. This belt polishing system provides a tuned stiffness that is
capable of conforming to the polishing surface without replicating the surface roughness. When combined with state of
the art figure correction algorithms, the UFF is capable of robust and deterministic figure correction for aspheric
surfaces.
Recently, OptiPro Systems has expanded the capability of the UFF to include deep concave ogive and free-form
surfaces. Although these types of surfaces can be beneficial from an optical or aerodynamic standpoint they pose
additional challenges both from their steep geometry as well as from a polishing tool path perspective. A brief
description of these challenges as well as possible solutions to these problems will be presented. In addition, the current
figure correction capability of the system utilizing feedback from OptiPro's five axis non-contact free-form metrology
system will be presented.
OptiPro Systems has been developing the UltraSurf, a non-contact measuring system using state of the art, precision
motion control. The goal is to precisely scan standard optical shapes such as concave and convex spherical surfaces, as
well as the complex geometries of aspheric, ogive, and freeform shapes without the limitations associated with other
measurement methods. Common optical measurement methods have limitations with surface roughness, slope error, and
deviation from best-fit sphere. Optipro designed the UltraSurf to further the manufacturing capabilities of companies
generating complex precision optics.
The UltraSurf measures with sub-micrometer non-contact point sensors to collect surface information. Various sensors
are commercially available from multiple companies, each with their own distinct optical measuring technology. One
optical sensor uses white light confocal chromatic imaging to measure individual optical surfaces. Another optical sensor
uses low-coherence interferometry with a near infrared laser, and is able to measure the inside, outside, and thickness of
optical materials at a single point.
The UltraSurf scans the optical sensors over the surface of the part under test, keeping it normal to the surface. The
single point measuring method coupled with computer-controlled motion gives the UltraSurf flexibility to measure
greatly varied geometries. Ultimately, a point cloud of the measured surface is generated. The cloud can be used to
calculate deviation from the desired shape, as well as various surface parameters. Applications, definitions, and
measurement results of freeform and conformal shapes using UltraSurf will be presented.
OptiPro Systems is developing a non-contact measurement system using state of the art motion control while minimizing the axes of motion during the measurement. The goal is to precisely scan concave and convex surfaces of aspheric, deep parabolic, and ogive shapes without the limitations associated with other measurement methods. The metrology systems will use different computer controlled slicing techniques to create a topographical surface map of the surface form with a high accuracy non-contact probe.
To achieve this precise scan the measurement system will incorporate sub-micrometer precision air bearings for the linear and rotary axes motion to minimize the effect of non-repeatable mechanical errors. Calibration of the measurement system will use high precision reference spheres. Finite element modeling and estimate has been used to predict and possibly compensate for mechanical flexures.
OptiPro has built a "breadboard" measurement system using a Professional Instruments air bearing and a STIL white light measurement pen. The results from the measurement of a near full hemispheric dome measurement will be presented as well as a comparison to the same dome measured using a stitching interferometer. The final system will incorporates complete computer controlled axes requiring as little operator training and set up as possible. The prototype system will utilize a non-contact pen for measurement. Current developments include the utilization of the STIL white light pen and the OptiGauge optical probe which utilizes invisible 1310 nm infrared light. The current system design and performance will be presented.
OptiPro Systems has developed a robust 5-axes computer controlled platform, for implementation of the sub-aperture
UltraForm Finishing (UFF) process specifically focused on finishing AlON, spinel and transparent polycrystalline
alumina (PCA) steep concave, convex and ogive shaped infrared domes and aspheres. Traditional manufacturing of
optical components typically involves a three-stage process: grinding, lapping and polishing. The lapping and polishing
stages are focused at reducing the surface roughness while preserving the integrity of the form acquired during grinding.
Polishing of non spherical and irregular shapes is nearly impossible using traditional full aperture techniques. However,
finishing these non-spherical and irregular shapes is possible using UltraForm Finishing.
A brief description of the evolution of the UltraForm hardware and processes will be presented, with the current
hardware developments. A review of the results with regard to form/figure and roughness improvements on glass, AlON
and transparent PCA will be presented using a variety of grinding and finishing abrasives. Differences in the abrasive
materials, some bound, and others loose in a slurry have a large impact on the process cycle time and resultant surface
roughness.
OptiPro Systems has developed a new finishing process for the manufacturing of precision optical components.
UltraForm Finishing (UFF) has evolved from a tire shaped tool with polishing material on its periphery, to its newest
design, which incorporates a precision rubber wheel wrapped with a band of polishing material passing over it. Through
our research we have developed a user friendly graphical interface giving the optician a deterministic path for finishing
precision optical components. Complex UFF Algorithms combine the removal function and desired depth of removal
into a motion controlled tool path which minimizes surface roughness and form errors.
The UFF process includes 5 axes of computer controlled motion, (3 linear and 2 rotary) which provide the flexibility for
finishing a variety of shapes including spheres, aspheres, and freeform optics. The long arm extension, along with a
range of diameters for the "UltraWheel" provides a unique solution for the finishing of steep concave shapes such as
ogives and domes. The UltraForm process utilizes, fixed and loose abrasives, in combination with our proprietary
"UltraBelts" made of a range of materials such as polyurethane, felt, resin, diamond and others.
A new compliant sub-aperture optical finishing technique is being investigated for the removal of mid-spatial frequency artifacts and smoothing of hard polycrystalline infrared ceramics for aspheric applications and conformal shaped optics. The UltraForm concept was developed by OptiPro Systems, Ontario, NY, and is a joint process development effort with the Center for Optics Manufacturing (COM). The latest version of the UltraForm tool "V3" is of a belted design whereby a belt of finishing material is passed over a toroidal elastomeric wheel. Finishing materials used include a wide variety of pad materials and abrasive selections. Experimentation has been conducted using both slurry mixes and fixed abrasive bands. The toroidal wheel is rotated while the compliant tool is compressed into contact with the optical surface. Presented will be the current results in optical glasses and crystalline ceramics such as ALON, Spinel and Polycrystalline Alumina.
A new compliant sub-aperture optical finishing technique is being investigated for the removal of mid-spatial frequency artifacts and smoothing of hard polycrystalline infrared ceramics for aspheric applications and conformal shaped optics. The UltraForm concept was developed by OptiPro Systems, Ontario, NY, and is a joint process development effort with the Center for Optics manufacturing (COM). The UltraForm tool is a pressurized, elastomeric bladder in the shape of a toroid. Finishing pads are attached to the periphery, allowing the use of a wide variety of pad materials and abrasive selections. Experimentation has been conducted using both slurry mixes and fixed abrasive pads. The toroidal tool is rotated while the compliant tool is compressed into contact with the surface. Currently this process has specific interest for the finishing of conformal ALON Domes. Also to be discussed will be new versions of the UltraForm Tools which are currently be developed and tested.
A new compliant sub-aperture optical finishing technique is being investigated for the removal of mid-spatial frequency artifacts and smoothing of hard polycrystalline infrared ceramics for aspheric applications and conformal shaped optics. The UltraForm concept was developed by OptiPro Systems, Ontario, NY, and is a joint process development effort with the Center for Optics Manufacturing (COM). The UltraForm tool is a pressurized, elastomeric bladder in the shape of a toroid. Finishing pads are attached to the periphery, allowing the use of a wide variety of pad materials and abrasive selections. Experimentation has been conducted using both slurry mixes and fixed abrasive pads. The toroidal tool is rotated while the compliant tool is compressed into contact with the surface. Currently this process has specific interest for the finishing of conformal ALON domes. Also to be discussed will be new versions of the UltraForm Tool, which are currently being developed and tested.
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