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Manufacturing Insight: Cnc Lens Grinding
Precision CNC Machining for Optical Lens Components
Honyo Prototype delivers advanced CNC machining solutions engineered for the exacting demands of optical lens manufacturing. Our specialized capabilities in CNC lens grinding and precision component fabrication ensure sub-micron tolerances, exceptional surface finishes, and strict adherence to complex geometries required for high-performance lenses. Leveraging state-of-the-art 5-axis CNC systems and proprietary process controls, we machine critical lens elements from challenging materials including optical glass, fused silica, sapphire, and infrared ceramics. This precision foundation enables optimal light transmission, minimal wavefront distortion, and seamless integration into final optical assemblies.
Our end-to-end service encompasses rapid prototyping through low-volume production, with rigorous in-process metrology to validate form accuracy and surface quality at every stage. Unlike conventional machining providers, Honyo’s engineering team applies deep domain expertise in optical physics and material science to preemptively address thermal stability, stress-induced birefringence, and edge integrity challenges inherent in lens fabrication.
Transition seamlessly from design to production with Honyo’s Online Instant Quote platform. Upload CAD files to receive detailed manufacturability feedback and competitive pricing within hours—accelerating your path from concept to certified optical components.
| Key Capability | Technical Specification | Application Benefit |
|---|---|---|
| Positional Accuracy | ±1.5 µm | Ensures precise optical axis alignment in multi-element systems |
| Surface Roughness | Ra < 0.01 µm (post-polishing ready) | Minimizes light scatter and coating defects |
| Material Range | Optical glasses (N-BK7, SF11), crystals, ceramics | Supports UV to IR spectral applications |
| Lead Time | As fast as 5 business days (prototype) | Reduces development cycles for time-sensitive projects |
Technical Capabilities
CNC lens grinding is a precision machining process used to shape and finish optical components or lens housings with high accuracy. While traditional lens manufacturing often involves grinding and polishing of glass, CNC machining is typically applied to lens mounts, barrels, and enclosures made from metals and engineering plastics. The process leverages multi-axis CNC milling and turning to achieve tight tolerances and fine surface finishes required in optical and imaging systems.
The following table outlines the technical specifications for CNC lens grinding applications, focusing on 3/4/5-axis milling and turning, tight tolerance capabilities, and compatible materials including Aluminum, Steel, ABS, and Nylon.
| Parameter | Specification Details |
|---|---|
| Machining Process | 3-axis, 4-axis, and 5-axis CNC milling and CNC turning |
| Typical Applications | Lens barrels, optical mounts, precision enclosures, alignment fixtures |
| Tolerance Range | ±0.0001″ (±2.5 µm) to ±0.0005″ (±12.7 µm), depending on geometry and material |
| Surface Finish (Ra) | 8–32 µin (0.2–0.8 µm) for metals; 32–125 µin (0.8–3.2 µm) for plastics |
| Positioning Accuracy | ±0.00005″ (±1.27 µm) on high-precision 5-axis machines |
| Repeatability | ±0.00004″ (±1 µm) on calibrated systems |
| Tooling | Diamond-coated end mills, carbide tools, polycrystalline diamond (PCD) for plastics |
| Coolant/Lubrication | Mist coolant for metals; air cooling or minimum quantity lubrication (MQL) for plastics |
| Work Envelope (Typical) | Up to 20″ × 16″ × 12″ (508 × 406 × 305 mm) on 5-axis mills |
| Materials – Metals | Aluminum (6061, 7075), Stainless Steel (303, 316), Tool Steel (e.g., H13) |
| Materials – Plastics | ABS, Nylon (6/66), PEEK, Delrin (POM), acrylic (for non-optical structural parts) |
| Material Considerations | Aluminum: Lightweight, excellent machinability; Steel: High rigidity, wear resistance; ABS: Low cost, easy to machine; Nylon: High strength, low friction but prone to thermal expansion |
| Fixturing | Vacuum chucks, custom soft jaws, zero-point clamping systems for high repeatability |
| Inspection Tools | CMM (Coordinate Measuring Machine), optical comparators, laser probes, profilometers |
5-axis CNC machining is particularly advantageous for complex lens housing geometries, enabling undercuts, compound angles, and simultaneous multi-surface machining with minimal setup changes. Tight tolerances are maintained through thermal stability, rigid machine structures, and in-process probing. For plastics like ABS and Nylon, machining parameters are adjusted to minimize heat buildup and deformation, ensuring dimensional stability.
This level of precision ensures optimal lens alignment, structural integrity, and compatibility with downstream optical assembly processes.
From CAD to Part: The Process
Honyo Prototype CNC Lens Grinding Process Overview
Honyo Prototype executes CNC lens grinding through a rigorously controlled workflow designed for optical precision, material integrity, and rapid turnaround. This process accommodates complex geometries in materials like BK7, Fused Silica, Sapphire, and IR crystals, targeting surface accuracies down to λ/10 and surface roughness below 10Å RMS. Below is the detailed sequence:
Upload CAD
Customers initiate the process by uploading native CAD files (STEP, IGES, or native SOLIDWORKS) via Honyo’s secure client portal. Our system validates geometric integrity, confirming critical optical parameters including radius of curvature, center thickness, clear aperture, and edge specifications. Non-conforming files trigger immediate automated feedback, specifying required adjustments to meet manufacturability baselines.
AI-Powered Quoting Engine
Uploaded designs undergo real-time analysis by our proprietary AI quoting system. This engine cross-references optical material databases, grinding/polishing cycle time algorithms, and historical yield data to generate a technically validated quote within 2 hours. The output includes precise cost breakdowns, lead time projections, and preliminary risk flags—such as geometric features prone to chipping (e.g., ultra-thin edges <1.0mm) or aspheric deviations exceeding deterministic grinding capabilities.
Optical DFM Review
Engineers conduct a formal Design for Manufacturability review focusing exclusively on optical constraints. This phase verifies compatibility with our CNC grinding infrastructure, including:
Feasibility of generating required aspheric coefficients
Material stress limits during grinding (critical for brittle crystals)
Metrology alignment strategies for interferometric validation
Edge lift mitigation protocols for high-curvature surfaces
DFM outcomes are documented in a collaborative report, with actionable recommendations provided within 24 business hours. Iterations are managed through version-controlled CAD markups.
Precision Production
Approved designs enter production on dedicated CNC grinding platforms (e.g., OptoTech VMC 150U, Precitech Nanoform 700FG). The process sequence is:
1. Deterministic Grinding: Diamond-coated tools remove bulk material to within 50µm of final form using sub-aperture correction algorithms.
2. Fine Grinding/Polishing: Transition to pitch/polyurethane laps with cerium oxide or slurry-based polishing, achieving nanometer-level surface figures.
3. In-Process Metrology: Real-time interferometer (ZYGO GPI) and profilometer (Taylor Hobson) checks at defined checkpoints ensure adherence to tolerances.
Metrology Validation Summary
| Parameter | Standard Tolerance | Honyo Capability | Measurement Tool |
|——————–|——————–|——————|————————|
| Surface Accuracy | λ/4 | λ/10 | Phase-Shifting Interferometer |
| Surface Roughness | 20Å RMS | <10Å RMS | AFM / White Light Profilometer |
| Centration Error | 3 arcmin | <0.5 arcmin | Autocollimator |
| Diameter Tolerance | ±0.05mm | ±0.005mm | Coordinate Measuring Machine |
Certified Delivery
Final lenses undergo 100% inspection per ISO 10110 standards. Each shipment includes:
Full metrology report with interferograms and surface power maps
Material certification and coating verification (if applicable)
Cleanroom-packaged components in ISO Class 5 containers with humidity indicators
Traceability documentation linking serial numbers to machine logs and operator records
Delivery occurs via climate-controlled logistics with real-time shipment tracking, typically within 7–15 business days post-DFM approval. All processes are AS9100D and ISO 9001:2015 certified, ensuring compliance for aerospace, medical, and defense applications.
Start Your Project
Looking for precision CNC lens grinding services? Contact Susan Leo at [email protected] to discuss your project requirements. With our advanced manufacturing capabilities and quality control, we deliver high-accuracy optical components for demanding applications.
Our factory is located in Shenzhen, China, enabling fast turnaround and efficient production for both prototypes and high-volume orders. Reach out today to request a quote or technical consultation.
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