Technologies
Diamond Direct Cutting of Hardened Steel: Delta Optics NanoFab is one of the first and one of the leading companies in the world to apply ultrasonic vibration-assisted devices to diamond cut hardened steel optical inserts without nickel plating......
Freeform Error Compensation: The software developed in-house facilitates 3D form error compensation for molded plastic lenses. This results in a remarkable enhancement of form accuracy, with the PV form accuracy improving from 40 µm to under 3 µm......
Diamond Micro-Milling: In the era of miniaturization, where devices are becoming smaller and more intricate, diamond micro-milling is a crucial technology for producing these tiny optical components/inserts with accuracy......
Diamond Tool Resharpening: this diamond tool resharpening machine was fully developed in-house, capable of restoring the worn diamond tool to a condition as good as new......
Direct Diamond Cutting of Hardened Steel Optical Inserts without Nickel Plating
DONF has maintained its pioneering role as a company that was among the earliest to adopt and continues to be at the forefront globally, employing ultrasonic vibration-assisted devices in the production of industrial-grade, nickel-plating-free hardened steel optical inserts.
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By applying ultrasonic vibration to a diamond tool, the diamond tool's tip consistently retracts from the cutting zone, allowing the lubricant to rapidly cool the cutting zone. This cooling process ensures that the temperature remains well below the critical point for chemical interaction between the diamond and iron. This approach has resulted in a significant improvement in diamond tool cutting life in steel cutting.
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Hardened steel optical inserts provide 3 times longer tool life and 4 weeks less lead time than nickel-plated inserts.
Hardened steel optical inserts
- Form accuracy < 0.2 µm
- Surface roughness < 7 nm Ra.
- Limitation: insert diameter < Ø35 mm
Benefits of Hardened steel optical inserts vs nickel plated optical inserts:
- 3 times longer molding tool life
- 4 weeks less lead time
Diamond Cutting of Hardened Steel Insert with assistance of Ultrasonice Vibration
Hardened steel inserts
​Surface Roughness Ra < 7 nm (measured by Wyko White Light interferometer)
Freeform Fabrication and 3D Form Error Compensation Technology
Plastic freeform optics represents a fast technological advancement that enables optical designs to achieve compactness, reduced thickness, and lighter weight in comparison to traditional optical approaches. Nonetheless, the injection molding of freeform lenses faces the hurdle of maintaining high form accuracy due to shrinkage during the cooling process. Addressing this, DONF has pioneered a 3D free-form error compensation technology that has significantly enhanced the form accuracy of these lenses
The technology enables 3D free-form NC program generation and form error compensation.
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For optical mold inserts:
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Form accuracy PV < 0.8 µm
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Surface roughness < 5 nm Ra
For molded plastic lenses:
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improved form accuracy PV from 40 µm to 2.4 µm
