The cycle of each processing step for Micro Rod Lenses

Processing flow and cycle Description of Micro Rod Lenses (Technical Description)

UltraOpto Micro Rod Lenses, with their high precision concentricity and excellent optical uniformity, are widely used in high-end scenarios such as medical endoscopes, laser communications, and industrial inspection. The processing involves multiple precise procedures, with strict cycle control at each stage to ensure the stability and consistency of mass production. The following is the detailed processing flow and corresponding cycle description.

1. Core processing flow and Cycle (1000 pieces per batch, standard specification: diameter 0.5-5mm, length 30-50mm)

1. Base material selection and preform preparation (2-3 days)

Select  high-purity optical glass (such as BK7) or crystal materials, and laser-cut them to remove impurities to make the initial blanks.

The blank is drawn into a preform slightly larger than the target diameter by an optical fiber drawing machine, with the diameter deviation controlled within ±0.01mm.

Cycle description: Material inspection takes 0.5 days, wire drawing and forming takes 1.5-2.5 days, the larger the batch, the higher the efficiency.

2 .Precision Etching and cutting (1-2 days)

Roughen the surface of the preform using a hydrofluoric acid etching process, precisely controlling the diameter to the target size.

Using  femtosecond laser cutting technology, the micro-rod lens blanks were cut to the set length, with smooth cuts and no burrs.

Cycle description: Corrosion treatment takes 0.5-1 day, laser cutting and stress relief treatment takes 0.5-1 day.

3. High temperature annealing stress release (7-7.5 days)

Place the blank in the annealing furnace and anneal it at a constant temperature of 495 ° C ±5 ° C for 174 hours      (about 7.25 days) to completely eliminate the internal stress generated during drawing and cutting.

The annealing process is carried out at a slow rate of temperature rise and fall (50 ° C /h) to ensure that the optical uniformity is restored to the optimal state.

Cycle description: The standard annealing cycle is 7 days, and the high-precision custom version needs to be extended to 7.5 days.

4. Ultra-precision grinding and polishing (3-4 days)

Rough grinding:Use W40-W28 emery for grinding to remove surface defects and reduce the      surface roughness to the micron level, which takes 1 day.

Fine grinding: Gradually refine the abrasive to W5 to achieve sub-micron surface roughness, taking 1 day.

Fine polishing: Using an asphalt polishing die in combination with cerium oxide polishing fluid to achieve an ultra-smooth surface with Ra≤0.01μm, it takes 1-2 days.

Cycle description: The higher the precision requirement, the longer the fine polishing cycle. For batch processing, the time can be reduced synchronously through multi-station equipment.

5.Centering and edge processing (1-1.5 days)

Calibrate the optical axis and the mechanical axis using an autocollimator, with eccentricity tolerance controlled at ≤5μm, to ensure  that the concentricity meets the standard.

Use diamond grinding wheels for 0.2mm×45° chamfering to avoid edge chipping and scattering.

Cycle description: Centering calibration takes 0.5 days, and chamfering and cleaning take 0.5-1 day.

6. Coating (optional) (2-3 days)

For specific band requirements, an anti-reflection or reflective coating is applied in a vacuum environment (vacuum degree ≥10⁻⁴Pa) with a  transmittance of over 99.5%.

The thickness of the film is monitored in real time through a crystal controller, with deviations controlled within ±2nm to ensure stable optical performance.

Cycle descriptin: 0.5 days for film system design and coating preparation, 1.5-2.5 days for coating and annealing stabilization treatment.

7.Full-process inspection and packaging (1-2 days)

Inspection      items: Surface shape accuracy (λ/[email protected]), dimensional tolerances, surface defects (conforming to MIL-PRF-13830B standard), optical properties, etc.

Qualified products are stored in anti-static packaging, sealed with desiccant and accompanied by inspection reports for quality traceability.

Cycle description: Batch inspection takes 0.5-1 day, packaging and report  preparation takes 0.5-1 day.

UltraOpto processing cycle Advantage

Standardized process control: 

Clear timeframes are set for each process, and the batch production cycle is stable and controllable.

Efficient equipment support: 

Use multi-station grinding and polishing machines and automated coating equipment to enhance processing efficiency.

Customized flexible adaptation: 

Urgent orders can be activated through a green channel, and regular models can be delivered within 12 days at the fastest.