The cycle of each processing procedure for ADJUSTABLE ASPHERIC COLLIMATORS

ADJUSTABLE ASPHERIC COLLIMATORS (adjustable aspheric collimators) are high-end optical devices that integrate aspheric optical design with precise adjustable structures.

Their processing combines core technologies such as ultra-precision optical processing, micro-nano assembly, and automated alignment and debugging, and strictly adheres to strict quality control standards throughout. The following is a detailed breakdown of the standard cycle for each processing step (based on batch production; the cycle for single set customization can be adjusted according to specifications), clearly presenting the complete cycle from raw materials to finished products for customer reference and planning. 

I. Core raw material selection and pretreatment cycle (2-3 days) 

As the foundation of product performance, the selection and pre-treatment of raw materials strictly adhere to industrial-grade high-end standards, ensuring that each component meets the requirements and that the cycle is stable and controllable. 

Raw material screening (1 day): 

Focus on selecting core materials such as aspheric lens substrates (quartz glass, high-transparency optical glass), adjustable mechanical components (low thermal expansion coefficient ceramics, Kovar alloy), optical fiber pigtails, and optical adhesives. The screening is conducted using high-power microscopes and material performance testing instruments to eliminate impurities and materials that do not meet performance standards, ensuring that the substrate's light transmittance and thermal stability meet design requirements. For aspheric lens substrates, curvature compatibility needs to be confirmed in advance, and the selection is carried out in accordance with the standards for precision aspheric processing materials. 

Raw material pretreatment (1-2 days):

 Clean and cut the qualified base materials. For optical glass base materials, remove surface stains and oxide layers. For mechanical structural components, perform initial grinding to remove burrs. For optical fiber tails, strip the outer sheath and coating. At the same time, subject all raw materials to constant temperature drying treatment (control the environmental temperature at 20±1℃) to prevent deformation or performance deviation during subsequent processing. After the pretreatment is completed, conduct a secondary spot check to ensure compliance with processing standards. 

II. Precision processing cycle for aspheric lenses (7-10 days) 

Aspheric lenses, as core optical components, have their processing accuracy directly determining the collimation effect. Micro-nano processing and precision polishing techniques are adopted, and the processing is completed in stages. The processing cycle is as follows: the entire process is carried out in a constant temperature, humidity, and clean workshop to avoid temperature drift affecting the processing accuracy. 

1. Substrate cutting and rough grinding (2 days): 

High-precision cutting equipment is used to cut the optical glass substrate into the preset size with an error controlled within ±0.001mm. Subsequently, the excess material is removed through the rough grinding process to initially form the aspheric contour. The grinding is carried out using a disc-shaped grinding wheel, with the cutting path moving from the edge to the center, quickly removing over 90% of the machining allowance and laying the foundation for the fine grinding process. 

2. Fine grinding and surface shape calibration (3-4 days): 

Utilizing CNC grinding and polishing technology, the process is carried out in layers with a cutting depth of 0.01mm. In-situ detection technology is employed to sample and measure surface shape data at intervals of 50μm, and the processing parameters and grinding wheel trajectory are adjusted in real time to correct surface shape errors. This ensures that the aspheric contour precisely matches the design requirements, with wavefront aberration ≤λ/10 (λ=632.8nm), and the surface roughness is controlled to be below 0.1nm. The process is executed in accordance with high-precision aspheric CNC processing technology standards. 

3. Precision polishing and anti-reflection coating (2-4 days): 

Fine polishing is carried out using magnetic fluid finishing (MRF) technology to further optimize the surface smoothness and remove the marks left by fine grinding. Then, anti-reflection coatings are applied according to the suitable wavelengths (350nm - 2300nm) to reduce light reflection loss and enhance light transmission. After coating, adhesion tests are conducted on the coating layer to ensure there is no peeling or scratches. Finally, an initial performance check of the lens is performed. 

III. Processing cycle for adjustable mechanical structural components (5-7 days) 

The adjustable mechanical structure (adjustment cylinder, guide sleeve, lens mounting seat, etc.) must ensure smooth adjustment and structural stability. It is processed by CNC precision machine tools. The processing cycle is as follows, with the core control being the dimensional accuracy and coaxiality: 

1. Numerical control processing (3-4 days): 

The ceramic and Kovar alloy substrates are processed through a five-axis CNC machine tool. The dimensional accuracy, coaxiality and thread accuracy of each component are strictly controlled (thread pitch 0.2mm, adjustment clearance 0.005-0.015mm). The adjustable interface of the adjustment sleeve is integrally formed, and the limit structure is reserved in the guide sleeve. The entire process adopts thermal balance compensation technology to offset the slight displacement caused by environmental temperature differences and ensure processing accuracy. 

2. Surface Treatment and Inspection (2-3 days): 

After processing, the mechanical components undergo surface anti-corrosion treatment (gold plating, passivation) to enhance wear resistance and corrosion resistance, and surface burrs are removed. Subsequently, high-precision image scanning inspection is carried out, with a focus on controlling concentricity and dimensional deviation to ensure compliance with assembly requirements. Non-conforming components are reworked, and the inspection is conducted in accordance with the precision collimator seat processing and inspection standards. 

IV. Fiber pigtail processing cycle (1-2 days) 

1.The core of fiber pigtail processing is to ensure efficient coupling with aspheric lenses. 

The process is simple but requires high precision, and the cycle is controllable. 

End face grinding (0.5 - 1 day): Utilizing precision grinding equipment, the end faces of optical fibers are polished. The grinding is carried out according to the interface type (PC/UPC/APC), with the APC interface ground to an 8° bevel. The angle tolerance is controlled within 101.79° ± 0.025° to ensure that the angle between the optical fiber end face and the lens optical axis meets the preset requirements. 

2. Cleaning and Inspection (0.5 - 1 day): 

Use lint-free cotton swabs dipped in anhydrous ethanol to precisely clean the fiber end faces, removing grinding debris. Inspect the fiber mode field diameter and end face flatness to ensure there are no impurities or scratches, which could affect coupling efficiency. 

V. Precision Assembly and Active Alignment Debugging Cycle (4-6 days) 

This process is the core procedure, directly determining the adjustable precision and optical performance of the product. It is carried out throughout in a 10,000-level clean workshop, and the cycle is as follows: 

1. Pre-installation and Fixation (1-2 days): 

Pre-install the aspheric lens and fiber pigtail respectively onto the mechanical structural components, and fix them using high-stability optical adhesives (353ND glue, UV305 glue). After UV curing and baking in an oven (bake at 85°C for 1-2 hours and at 110°C for 2-3 hours), ensure the assembly is firm and free from looseness, and conduct preliminary optical axis alignment at the same time. 

2. Active alignment and adjustable debugging (2-3 days): 

Utilize a six-dimensional adjustment platform in conjunction with a beam analyzer, a CCD image recognition system, and a low-power visible alignment laser. Fine-tune the Zθ adjusters of the adjustment cylinder to drive the movement of the tilt plate for precise optical axis adjustment. Simultaneously, monitor the collimation accuracy and coupling efficiency to ensure that the collimation accuracy is ≤ 0.1 mrad and the coupling efficiency is ≥ 95%. Lock the debugging parameters to ensure smooth adjustable functionality, and follow the reference standards for the alignment system debugging of fiber collimators. 

3. Sealing treatment (1 day): 

After the fine-tuning is completed, the interior of the product is sealed to prevent dust and moisture from entering. At the same time, the assembly tightness and adjustability are checked again to ensure there is no looseness or deviation. 

VI. Multi-dimensional Quality Inspection and Aging Test Cycle (3-5 days) 

Full-process quality inspection and aging tests are carried out to ensure stable product performance and compliance with factory standards. The cycle is as follows, and the inspection is conducted in accordance with the optical element surface shape inspection and collimator performance inspection standards: 

1.Optical performance testing (1 day): 

Test the collimation accuracy, insertion loss (≤0.3dB), return loss (APC interface ≥ 60dB), polarization-dependent loss (≤0.1dB), and beam uniformity. Build the test optical path using a standard collimator, calculate the divergence angle through the spot size, and ensure it meets the design requirements. 

2. Mechanical performance and environmental adaptability testing (1-2 days): 

Check the smoothness of mechanical component adjustment and the firmness of the structure, conduct anti-vibration and anti-shock tests (in compliance with military standard GJB 150A), and perform high and low temperature cycling tests (-40℃ to 85℃, 50 cycles) to ensure no performance fluctuations. 

3. Aging Test and Final Inspection (1-2 days): 

Conduct short-term aging tests (72 hours) to verify the long-term stability of the product. At the same time, perform final inspections on appearance and performance parameters. Unqualified products will be reworked or scrapped, while qualified products will be numbered, filed, and equipped with test reports. The optical component aging test standard will be followed for execution. 

VII. Summary and Explanation of the Overall Cycle 

The overall production cycle for standard batch production (≥50 sets) of ADJUSTABLE ASPHERIC COLLIMATORS is 22-33 days. The production cycle for single set customized products (with special specifications, special wavelengths or interfaces) can be extended by 3-7 days based on customized requirements. All process cycles have been strictly calculated and verified through practice. Relying on digital production processes and precision processing equipment, the cycle can be ensured to be stable and controllable, while also taking into account product accuracy and performance. 

If the customer has an urgent need, they can contact our technical and production teams to optimize the production scheduling plan. Under the premise of ensuring product quality, the overall cycle can be shortened by 10% to 20%. We will provide full-cycle progress tracking services throughout the process to ensure on-time delivery.