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

Lukin, A.V., Gurin, N.A., Melnikov, A.N., Lisova, E.G., Svistunova, A.A.

Publication in Journal of Optical Technology

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. http://doi.org/10.17586/1023-5086-2023-90-07-107-115

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. http://doi.org/10.17586/1023-5086-2023-90-07-107-115

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). https://doi.org/10.1364/JOT.90.000417

Abstract:

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.

Keywords:

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

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