ru/ ru

ISSN: 1023-5086


ISSN: 1023-5086

Scientific and technical

Opticheskii Zhurnal

A full-text English translation of the journal is published by Optica Publishing Group under the title “Journal of Optical Technology”

Article submission Подать статью
Больше информации Back

DOI: 10.17586/1023-5086-2023-90-07-107-115

Experimental use of precision replication technology to recover optical parts from rejects in batch production

For Russian citation (Opticheskii Zhurnal):

Лукин А.В., Гурин Н.А., Мельников А.Н., Лисова Е.Г., Свистунова А.А. Опыт применения технологии прецизионного реплицирования для восстановления оптических деталей из брака при серийном производстве // Оптический журнал. 2023. Т. 90. № 7. С. 107–115.


Lukin A.V., Gurin N.A., Melnikov A.N., Lisova E.G., Svistunova A.A. Experimental use of precision replication technology to recover optical parts from rejects in batch production [in Russian] // Opticheskii Zhurnal. 2023. V. 90. № 7. P. 107–115.

For citation (Journal of Optical Technology):

Anatoly V. Lukin, Nikita A. Gurin, Andrei N. Melnikov, Elena G. Lisova, and Alisa A. Svistunova, "Experimental use of precision replication technology to recover optical parts from rejects in batch production," Journal of Optical Technology. 90(7), 417-421 (2023).


Subject of study. The article considers the possibility of using the technology of precision replication of aspherical surfaces in batch and mass production of optical parts in order to recover defective lenses and mirrors, namely to correct working surface defects such as shape, surface finish class, and roughness parameters. The aim of study is to inform the managers and technologists of optical enterprises about the unique restoration abilities of this technology. Method. An experimental method has been implemented to restore optical elements from rejects according to the shape of the aspherical surface using precision replication technology (i.e. the manufacture of combined optical elements with one replicated aspherical surface). Several samples of a glass lens were restored, to which an appropriate antireflection coating was applied. Comprehensive tests of restored optical parts with the antireflection coating were carried out. Using them, the moduli of the optical transfer function of optical devices were experimentally measured. Main results. A trial batch of biconvex glass lenses with a single replicated aspherical surface intended for a commercial product eyepiece has been recovered from rejects discarded due to aspherical surface shape defects. An interferometric testing of the recovered samples has been conducted using a Twyman–Green interferometer with a computer-generated holographic optical compensator element. Based on the results obtained, three best samples were selected for further testing. The results of comprehensive tests of one of them are presented in the paper, including measurement results of the optical transfer function modulus of an eyepiece assembled using this sample. Practical relevance. During batch and mass production of objectives and eyepieces of various purposes, a noticeable number of optical parts (lenses and mirrors) inevitably gets rejected by quality department due to their working surface defects (root-mean-square deviation, surface finish class, and roughness level). Implementing the suggested technology opens up a viable opportunity to recover a substantial amount of such parts.


precision replication, aspherical optics, optical surface quality defects, optical surface recovery, laser-holographic interferometer, computer-generated holographic optical compensator element, optical production, objectives and eyepieces of various purposes

OCIS codes: 240.6700, 160.5470, 220.3630, 230.4040, 220.1250, 090.2880, 090.2890, 220.4610, 220.4840, 120.4820, 120.4630


1. Karlin O.G., Kuks V.G., Lipovetsky L.E., et al. Manufacture and testing of aspherical optical elements [in Russian]. Moscow: Central Research Institute of
Information, 1980. 272 p.
2. Lukin A.V., Melnikov A.N. Precision replication of all types of optical surfaces — scientific and technological basis for radical transformation of modern optical production // J. Opt. Technol. 2022. V. 89. № 10. P. 589–594.
3. Lukin A.V., Melnikov A.N., Akhmetov M.M., et al. Replicated aspherical optical elements. Main aspects of organizing mass and batch production [in Russian] // Kontenant. 2017. V. 16. № 2. P. 167–172.
4. Belozerov A.F., Larionov N.P., Lukin А.V., et al. On-axis computer-generated hologram optical elements: History of development and use. Parts 1, 2 [in Russian] // Photonics Russia. 2014. № 4. P. 12–32; № 5. P. 30–41.
5. OST (Industry Standard) 3–4730–80 – OST 3–4732–80. Collection of industry standards. Optical parts withaspherical surfaces. A testing method involving computer-generated holograms [in Russian]. Introduced on January 1, 1981. Moscow: “Kompleks” Central Research Institute Publishing,1980. 69 p.
6. GOST R (Russian National Standard) 59737–2021. Optics and photonics. Optical hologram computer-generated on-axis elements. General specifications [in Russian]. Introduced on March 1, 2022. Moscow: Russian Institute of Standardization, 2021. 40 p.
7. OST (Industry Standard) 3–1901–95. Coatings of optical parts. Types, main parameters and testing methods [in Russian]. Introduced on September 1, 1995. Moscow: “Kompleks” Central Research Institute Publishing, 1995. 191 p.
8. GOST (Russian National Standard) 11141–84. Optical parts. Surface finish classes. Methods of control [in Russian]. Introduced on January 1, 1985. Moscow: Standards Publ., 1984. 15 p.
9. Afanasyev V.A. Optical measurements [in Russian]. Moscow: Vysshaya Shkola Publ. 1981. 229 p.
10. Smith W.J. Modern optical engineering. The design of optical systems. N.Y.: SPIE Press, 2008. 754 p.
11. Braat J.J.M., Smid A., Wijnakker M.M.B. Design and production technology of replicated aspheric objective lenses for optical disk systems // Appl. Opt. 1985. V. 24. № 12. P. 1853–1855.
12. Zwiers R.J.M., Dortant G.C.M. Aspherical lenses produced by a fast high-precision replication process using UV-curable coatings // Appl. Opt. 1985. V. 24. № 24. P. 4483–4488.
13. Zwiers R.J.M., Braat J.J.M., Dortant G.C.M. A replicated bi-aspherical readout lens for optical disc systems // Proc. SPIE. 1986. V. 645. P. 53–57. 10.1117/12.964486
14. Zwiers R.J.M. Materials for replication technology — a fast & high-precision manufacturing method for optical components // Materials & Design. 1987. V. 8. № 3. P. 170–175.
15. Voskovtseva L.M., Davletshina Z.Yu., Kamardin Yu.B., et al. Research of polymeric materials for manufacturing transmitting copies of diffraction optical elements for UV spectral range [in Russian] // Opticheskaya Tekhnika. 1995. № 3(7). P. 33–34.
16. Handbook of optical engineering / Eds Malacara D., Thompson B.J.. N.Y. — Basel: Marcel Dekker, Inc., 2001. 978 p.
17. Okatov M.A., Antonov E.A., Baygozhin A., et al. Optical technologist’s handbook [in Russian] / Ed. Okatov M.A. St. Petersburg: Politekhnika Publ., 2004. 679 p.
18. Serova V.N. Optical and other materials based on transparent polymers [in Russian]. Kazan: KSTU, 2010. 540 p.
19. Wang Q., Zhao Yu., Zhang L., et al. New exploration of the optical aspherical replication technique // Proc. SPIE. 2010. V. 7655. P. 76551S-1–76551S-5.
20. Serova V.N. Polymeric optical materials [in Russian]. St. Petersburg: NOT Publ., 2015. 382 p.
21. Zhdanova A.V., Mikhailov V.N., Babkin O.E., et al. Low shrinkage photo-polymerizing compositions for precision replication of diffraction and aspherical optical elements. First results and prospects [in Russian] / Innovative materials and technologies in the field of design // Collection of abstracts from the 3rd All-Russian Sci. Conf. Featuring Young Researchers. 2017. St. Petersburg: SPbGIKiT, 2017. P. 26–27.