Breakthrough to new method in laser optics
Wafer-based mass production of high-precision glass optics for diode laser applications
(PresseBox) - Quantity and quality
LIMO GmbH, a manufacturer of high-precision micro-optics for laser systems, has achieved a process-engineering breakthrough in the production of FAC lenses for all types of diode-pumped laser sources. The Dortmund-based company has made it possible to mass-produce the lenses with superior precision.
FAC lenses for laser systems are a key component in many innovative technologies. They are already used in the aerospace industry, medical technology, photovoltaics, display manufacturing, and materials processing, but batch sizes are expected to see another major increase thanks to the use of the lenses in additive manufacturing (3D printing) and LIDAR systems (laser-based Light Detection and Ranging). The LIDAR systems for autonomous driving are a component that is particularly important to safety, and are also used in harsh ambient atmospheres. Aside from high quality, they also need to deliver reliable operation with long-term stability. The only way to meet these requirements is with laser systems that utilize high-end glass micro-optics.
The component most critical to the quality of these systems is the fast-axis collimator lens (FAC lens), which is manufactured from high-grade glass and has an acylindrical surface. However, currently available production methods have yet to demonstrate that they are capable of producing quantities on the order of several tens or hundreds of millions of pieces at a consistently high optical quality, and at attractive prices. But now, LIMO has succeeded in making the process for manufacturing FAC lenses that provide the demanded quality suitable for high-volume production.
140-mm wafers for the production of FAC lenses
LIMO GmbH produces the FAC lenses on wafers, which allows several thousand lenses to be fabricated from high-grade glass in a single step. When mass-producing highly complex glass optics, manufacturers face the challenge of processing large wafer areas with a consistently high level of precision. With a wafer size of 140
In the glass molding process that has typically been used up to now, glass lenses are processed at high temperatures of approx. 600?800uctuations occur during the heating process, and these fluctuations can only be minimized by implementing very costly process-control measures. Because of these limitations, this ?hot? production method has a number of drawbacks where large quantities are involved, and is not fully scalable.
The unique feature of the LIMO method is that the glass lenses are produced at room temperature. The company was able to increase the wafer size while also reducing the cycle time per wafer to under 60
The secret to quality: a high-precision grinding process
?We have the ability to process 140-mm and larger glass wafer discs without stress, in large quantities. To do so, we make all of the tools and nearly all of the machines used for the fabrication process in-house. This gives us maximum flexibility when it comes to the geometries and the design of the lenses. To ensure extremely high lens quality in high volume production, we have developed an automated high-precision grinding process. There is nothing else like it in the world,? says Dirk Hauschild, Chief Marketing Officer (CMO) at LIMO GmbH.
Using the cold grinding and polishing method developed by LIMO for cylindrical lens arrays, up to 20
In a single grinding process, up to several millimeters must be removed from the glass surface with an accuracy of just a few nanometers. The lenses must also undergo final polishing as a last process step. The high-grade surface quality is achieved by areal polishing, which further increases the durability and stability of the glass surfaces. With its high-precision grinding process, LIMO has reached performance levels at the limit of the physically possible (see info box below).
The goal for 2019: manufacture over 5
The 140-mm glass wafers are processed 24tes Chief Operating Officer (COO) Dirk Bogs in summarizing the production standard achieved thus far.
Info box: FAC lenses for single emitter diodes
Fast-axis collimator lenses (FAC lenses) are mainly used with single emitter diodes. These lenses are designed for a small beam width (collimation width) and are therefore optimized for materials processing and for diode-laser pumping applications.
The FAC lenses from LIMO, such as the FAC
Standard focal length of ?
Low-absorption coating (VIS to FIR)
Low residual divergence with high power content
High-index materials (> 1.8)
Transmission > 99% across a broad spectrum (e.g., 770?1070 nm)
Since its inception in 1992, LIMO GmbH has been one of the world?s leading manufacturers of optics and beam shaping solutions, as well as a pioneer of groundbreaking new photonics production technologies. The company develops and produces high-precision micro-optics for diode lasers, industrial laser systems for innovative materials processing, and complete optical systems for efficient production processes that use linear laser beam profiles. In the field of optical components, LIMO is currently one of the world?s major suppliers of glass cylindrical lenses thanks to its highly productive wafer-based manufacturing technology. With its innovative optics and laser system solutions, the company serves customers from all over the world in a wide range of different industries, including the laser, display production, semiconductor manufacturing and automotive industries, and the fields of measurement engineering, plastics processing and medical technology. LIMO is headquartered in Dortmund, Germany, and currently employs 230 people. The company has been part of the Focuslight Group since March 2017.
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Since its inception in 1992, LIMO GmbH has been one of the world?s leading manufacturers of optics and beam shaping solutions, as well as a pioneer of groundbreaking new photonics production technologies. The company develops and produces high-precision micro-optics for diode lasers, industrial laser systems for innovative materials processing, and complete optical systems for efficient production processes that use linear laser beam profiles. In the field of optical components, LIMO is currently one of the world?s major suppliers of glass cylindrical lenses thanks to its highly productive wafer-based manufacturing technology. With its innovative optics and laser system solutions, the company serves customers from all over the world in a wide range of different industries, including the laser, display production, semiconductor manufacturing and automotive industries, and the fields of measurement engineering, plastics processing and medical technology. LIMO is headquartered in Dortmund, Germany, and currently employs 230 people. The company has been part of the Focuslight Group since March 2017.
Datum: 10.01.2019 - 04:27 Uhr
Sprache: Deutsch
News-ID 1545582
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