High-Precision Freeform Surface Processing through Ultra-Precision Machining - Crystal Optics -
Direct cutting finishes the surfaces of free-form shapes made of materials such as aluminum and resin with high precision at the micrometer and nanometer levels.
In fields where advanced technologies such as space, astronomy, and new energy are adopted, high-precision component manufacturing is required. In crystal optics, advanced freeform surface shapes are created using machining methods with lathes. 【Processing Achievements】 ● Head-Up Display Aluminum ultra-large freeform mirror 600x200mm * Shape accuracy: PV 1μm * Roughness: Ra 1nm ● Washers, Spherical Bearings Ni2P (Electroless Nickel) surface concave φ100mm * Shape accuracy: PV 2μm * Roughness: Ra 3nm ● Astronomy, Space Infrared Observation Device Mirror Prototype mirror for the 30m-class TMT telescope at the University of Tokyo Atacama Observatory ● Fine groove mirror surface processing, diffraction gratings (shaping processing) ● Electroforming processed surface precision cutting ● Mirror tubes ● Resin lenses ● Molds ● Stampers (fine structure patterns)
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basic information
【 Use of Processing Machines and Measuring Instruments 】 ● Processing Machines - Ultra-precision processing machine "IL600" Manufacturer: INNOLITE (Germany) <Features> - In addition to the 4-axis configuration of XYZC, it is equipped with a W-axis (referred to as Over Drive). - The W-axis has the same driving direction (forward and backward) as the Z-axis, but unlike the Z-axis, which drives the entire stage, only the tool holding part moves, allowing for high-speed drive (stroke of 50mm). - Not only can it perform 3-axis synchronous processing (STS processing) of XZC, but it can also shorten processing time for free-form surfaces using the W-axis. - It achieves high precision tracking based on a unique algorithm called DirectDrive. - It completes temperature and water cooling environments within the processing machine itself, demonstrating high performance. ● Processing Machines - Ultra-precision lathe processing machine "Nanoform" Manufacturer: Ametek Precitech (Precitech Inc.) ● Measuring Instruments - Non-contact surface profile measuring machine "New View" - Large diameter laser interferometer "Verifire" Manufacturer: Zygo - Ultra-high precision three-dimensional measuring machine "UA3P" Manufacturer: Panasonic
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Applications/Examples of results
Fields: Space & Astronomy, Automotive, Medical, Precision Equipment Parts, Others
Detailed information
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- Prototype machining parts for the next-generation image slicer unit for the TMT 30m-class large telescope's mid-infrared observation device MICHI (Joint development and prototyping by Associate Professor Itsuki Sakon, Department of Astronomy, Graduate School of Science, University of Tokyo) - Fabrication of a multi-curved integrated mirror that pairs with the slice mirror - Guaranteeing the positional accuracy of each mirror through one-chucking machining of multiple mirrors with mechanical precision. - The relative positional accuracy of multiple off-axis aspheric mirrors is ensured with ultra-precision machining accuracy through one-chucking machining. - Mirror material: A6061
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- Fabrication of mirrors for the mid-infrared spectroscopic imaging device MIMIZUKU, which will be mounted on the infrared telescope of the Tokyo University Atacama Observatory (TAO) project. The mirrors were assembled while simultaneously adjusting the optical path and measuring on the measurement device. - A total of 50 mirrors, including three types of shapes: flat mirrors, aspheric mirrors, and freeform mirrors.
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- Prototype mirror production for the next-generation infrared space telescope's image slicer-type near-infrared spectrometer unit. - Joint production of the prototype mirror and image slicer unit for the SPICA project with Nano Optonics Energy Co. Achieving high precision requirements through ultra-precision machining technology. - Utilizing slot tool servo machining with a diamond turning center allows for simultaneous processing of multiple spherical designs with different specifications. Additionally, simultaneous processing with a single chuck minimizes errors for each spherical surface. - Not only for the spherical parts but also for the precision machining of reference surfaces, which are crucial during processing and assembly, all operations can be performed in-house. Furthermore, by conducting all processes in-house, significant reductions in delivery time are possible.
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- 600×200mm 20kg. Enables the provision of ultra-large and high-precision freeform optical components. - Practical implementation of simultaneous 3-axis machining (X, Z, C) through spindle rotation synchronization. By developing slotted tool servo machining, we successfully synchronized the spindle's rotation angle (C-axis) with the tool coordinates (XZ-axis), achieving practical machining of asymmetrical curved surfaces (freeform) on the rotation axis. - In crystal optics, it is possible to process large-diameter and high-precision freeform mirrors with a maximum diameter of φ700mm.
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The Nanoform700ultra makes the most of its maximum stroke of φ700, enabling the scaling up of high-precision freeform optical products. The forward and backward drive distance (sag amount) of the tool at the outermost circumference is 20mm, with a maximum forward and backward drive speed of 2000mm/min.
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Company information
Our company, at the time of its founding, was engaged in the hand polishing of optical single crystals. Among optical crystal materials, there are extremely delicate materials that can only be polished in environments with strict control of temperature and humidity. Based on this polishing technology, we have been involved in the polishing of various materials up to the present day. Now, after 30 years, we have expanded our capabilities to handle not only single crystals but also all kinds of materials including metals, non-metals, and ceramics. Initially, we processed small components that could fit in the palm of a hand, but today we are capable of handling ultra-large components up to 8000mm. In terms of our business (processing), we are focusing on in-house integrated production to achieve higher precision processing. We have established six fields: cutting, grinding, polishing, ultra-precision processing, surface treatment (non-conductive treatment/electropolishing), and measurement, allowing our customers to provide just one drawing and entrust all processing to us. In November 2014, with the aim of engaging in the aerospace industry, we introduced two new 5-axis composite machining centers, and we will do our utmost to contribute to the aerospace industry, which promotes the evolution of space.
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