Research of Digital Manufacturing Technology Application on Ultra-precision Optical Workpiece Machining

Digital manufacturing technology can be used in optical field to solve many problems caused by traditional machining. According to the characters of digital manufacturing and the practical applications of ultra-precision machining,the process of digital ultra-precision machining and its technical contents were presented in this paper. In the conclusions,it was stated that the digitalization of ultra-precision machining will be an economical and efficient way for the production of new sorts of optical workpieces.

Fabrication and test of reaction bond silicon carbide for optical applications

A reaction bonding fabrication process using various grain size of SiC powder was investigated. The properties such as mechanical, thermal and physic property were tested and analyzed. RBSiC produced using this process is a polycrystalline material and has high specific stiffness (density of 3.09 g/cm3 with elastic modulus of 362.39 GPa), strength (269.64 MPa) and hardness (19.43 GPa). At room temperature its low CTE (3.47×10?6/K), combined with relatively high thermal conductivity (161.14 W/mK) and specific heat capacity (593.86 J/kg.K) can minimize the bothersome thermal distortion. This advantage is outstanding even at higher temperature of test range. Two d 250 mm RBSiC mirror were polished. Surface roughness value less than 5 nm was obtained. Results prove that this reaction bonding process is a feasible method to produced high quality RBSiC optical mirror.

Optical Measurements to Reveal Roles of Slightly Crosslinked Poly (dimethyldiallylammonium chloride) s in Fixing Anionic Dyes on Cotton Fabric

The roles of slightly crosslinked poly( dimethyldiallylammonium chloride) s( PDMDAACs) in fixing anionic dyes on cotton fabric were verified more precisely by optical analysis technologies,to achieve the new theoretical guides for the widely applications. Firstly,one method of optical CIELAB color difference analysis was designed to exactly measure the values of dyefixing performances, so that the suitable molecular weights and structures of the slightly crosslinked PDMDAACs could be precisely confirmed to play a role in the development of their dye-fixing performances. Secondly,the FT-IR absorption shift of the dye on dyed cotton sample fixed by slightly crosslinked PDMDAACs was nearly in agreement with that of forming water-insoluble color lakes,indicating that the expected color lakes could be formed on dyed cotton fabric,and would play a role in further development of the fastness of dyes on cotton fabric. Thirdly,the FT-IR spectra of fixed undyed cotton samples and that of fixed dyed cotton samples both showed the absorptions of slightly crosslinked PDMDAACs,further revealing that the slightly crosslinked PDMDAACs could be penetrated into cotton fabric and be convenient to interact with dyes when fixing. However,those absorptions of the slightly crosslinked PDMDAACs fixed on cotton samples would be absent after being adequately washed to a constant weight,suggesting that the fixing interactions of the slightly crosslinked PDMDAAC and cotton fabric were very weak.

Femtosecond laser fabrication of nanograting-based distributed fiber sensors for extreme environmental applications

The femtosecond laser has emerged as a powerful tool for micro-and nanoscale device fabrication. Through nonlinear ionization processes, nanometer-sized material modifications can be inscribed in transparent materials for device fabrication. This paper describes femtosecond precision inscription of nanograting in silica fiber cores to form both distributed and point fiber sensors for sensing applications in extreme environmental conditions. Through the use of scanning electron microscope imaging and laser processing optimization,high-temperature stable, Type II femtosecond laser modifications were continuously inscribed,point by point, with only an insertion loss at 1 d B m~(-1) or 0.001 d B per point sensor device.High-temperature performance of fiber sensors was tested at 1000℃, which showed a temperature fluctuation of ±5.5℃ over 5 days. The low laser-induced insertion loss in optical fibers enabled the fabrication of a 1.4 m, radiation-resilient distributed fiber sensor. The in-pile testing of the distributed fiber sensor further showed that fiber sensors can execute stable and distributed temperature measurements in extreme radiation environments. Overall, this paper demonstrates that femtosecond-laser-fabricated fiber sensors are suitable measurement devices for applications in extreme environments.

Present status of research on space optical remote sensors at CIOMP

This paper is to review our space optical remote sensor(SORS) technologies including optical materials, optics fabrication and coating, optical testing, system assembly and final testing, and space environment simulation experiment conducted in our institute. The primary parts of the fabrication and testing facilities and results are described in detail.

Block-free optical quantum Banyan network based on quantum state fusion and fission

Optical switch fabric plays an important role in building multiple-user optical quantum communication networks.Owing to its self-routing property and low complexity, a banyan network is widely used for building switch fabric. While,there is no efficient way to remove internal blocking in a banyan network in a classical way, quantum state fusion, by which the two-dimensional internal quantum states of two photons could be combined into a four-dimensional internal state of a single photon, makes it possible to solve this problem. In this paper, we convert the output mode of quantum state fusion from spatial-polarization mode into time-polarization mode. By combining modified quantum state fusion and quantum state fission with quantum Fredkin gate, we propose a practical scheme to build an optical quantum switch unit which is block free. The scheme can be extended to building more complex units, four of which are shown in this paper.

Tool path generation of ultra-precision diamond turning: A state-of-the-art review

With the increasing market demand for optical complex surface parts,the application of multi-axis ultraprecision single-point diamond turning is increasing.A tool path generation method is very important to decrease manufacturing time,enhance surface quality,and reduce cost.Compared with the tool path generation of the traditional multi-axis milling,that of the ultra-precision single-point diamond turning requires higher calculation accuracy and efficiency.This paper reviews the tool path generation of ultra-precision diamond turning,considering several key issues:cutter location(CL)points calculation,the topological form of tool path,interpolation mode,and G code optimization.

Research on Large Depth Diameter Ratio Ultra-precision Aspheric Grinding System

In this paper, the factors of affecting surface roughness and profiles accuracy of the machined larege depth diamter ratio aspheric surfaces in ultra-precision grinding process are analyzed theoretically. An ultra-precision aspheric grinding system is then designed and manufactured. Aerostatic form is adopted to build the spindle of the workpiece, transverse guideway, longitudinal guideway and the spindle of the grinder in this system. The following specification is achieved, such as the turning accuracy of the spindle of the workpiece is 0.05 μm, radial rigidity of the spindle is GE 220N/μm, axial rigidity is GE 160 N/μm, radial rigidity of the guideway is GE 200N/μm, the highest rotational speed of the grinder is 80 000 rev/min and its turning accuracy is 0.1 μm, the resolution of linear displacement of the transverse and longitudinal guideway is 4.9 nm. Adjusting range of this adjusting mechanism is 2 mm in the Y direction, the adjusting accuracy of the precise adjusting mechanism is 0.1 μm. Micro displacement measuring system of this ultra-precision aspheric grinding adopts two-backfeed strategy, and angle displacement back-feed is realized by photoelectric encoder, it’s resolution is 655 360 pulse/rev. after 4 frequency multiplication, it’s angle displacement resolution is achieved 2 621 440 pulse/rev. Straight-line displacement is monitored by single frequency laser interferometer (DLSTAX LTM-20B, made in Japan). This CNC system adopts inimitable bi-arc step length flex CN interpolation algorithm, it’s CN system resolution is 5 nm.So this aspheric grinding system ensures profile accuracy of the machined part. The resolution of this interferometer is 5 nm. Finally, lots of ultra-precision grinding experiments are carried out on this grinding system. Some optical aspheric parts, with profiles accuracy of 0.3 μm, surface roughness less than 0.01 μm, are obtained.

Research status and challenges in the manufacturing of IR conformal optics

The infrared conformal window is one of the most critical components in aircraft.Conformal windows with high performance bring low aberrations,high aerodynamic performance,reliability in extreme working environments,and added value for aircraft.Through the past decades,remarkable advances have been achieved in manufacturing technologies for conformal windows,where the machining accuracy approaches the nanometer level,and the surface form becomes more complex.These advances are critical to aircraft development,and these manufacturing technologies also have significant reference values for other directions of the ultra-precision machining field.In this review,the infrared materials suitable for manufacturing conformal windows are introduced and compared with insights into their performances.The remarkable advances and concrete work accomplished by researchers are reviewed.The challenges in manufacturing conformal windows that should be faced in the future are discussed.

Advances in the design and manufacturing of novel freeform optics

Freeform optics has become the most prominent element of the optics industry. Advanced freeform optical designs supplementary to ultra-precision manufacturing and metrology techniques have upgraded the lifestyle, thinking, and observing power of existing humans.Imaginations related to space explorations, portability, accessibility have also witnessed sensible in today’s time with freeform optics. Present-day design methods and fabrications techniques applicable in the development of freeform optics and the market requirements are focussed and explained with the help of traditional and non-traditional optical applications. Over the years,significant research is performed in the emerging field of freeform optics, but no standards are established yet in terms of tolerances and definitions. We critically review the optical design methods for freeform optics considering the image forming and non-image forming applications. Numerous subtractive manufacturing technologies including figure correction methods and metrology have been developed to fabricate extreme modern freeform optics to satisfy the demands of various applications such as space, astronomy, earth science, defence,biomedical, material processing, surveillance, and many more. We described a variety of advanced technologies in manufacturing and metrology for novel freeform optics. Next, we also covered the manufacturing-oriented design scheme for advanced optics. We conclude this review with an outlook on the future of freeform optics design, manufacturing and metrology.

Solving the input data in error correc-tion of optical fabrication by finite Fourier coefficient algorithm

A free-form lens (FFL) is a special surface that is difficult to be fabricated. FFL are usually fabricated by computer-controlled optical surfacing (CCOS) technique. During CCOS, the material removal amount is determined by the unit removal function (URF) convoluting with the input data――the dwell time. When the removal amount and the URF are known, how to solve the input data involves the special algorithm――deconvolution. Usually, the input data are solved by virtue of low pass filter or iterative methods. However, an approximation solution would destroy the machining stability nec-essary to perform precisely CCOS. In this paper, to solve the input data, a new method that is based on the finite Fourier coefficient is put forward. It can give a continuous and accurate solution for fabricating choice. Several parameters are simulated, which influ-ence the process of CCOS, and evaluating on the effect of the method is also carried out. Experimental results verify that this method is suitable for guiding the manufacturing of high precision FFL.

Micro-optical fabrication by ultraprecision diamond machining and precision molding

Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression mold- ing or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultrapreci- sion machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.

Fabrication and near-infrared optical responses of 2D periodical Au/ITO nanocomposite arrays

Two-dimensional(2D) periodical Au and indium tin oxide(ITO) nanocomposite arrays have been fabricated based on a self-assembled nanosphere lithography technique. A button-shaped Au nanoparticle was formed on each hollow hemisphere-shaped ITO shell. Importantly, the underlying formation mechanism during the thermal treatment has been thoroughly explored by comparing structures resulting from different deposition conditions in detail. Compared to the Au nanoparticle arrays without ITO shells, the Au/ITO nanocomposite arrays showed a stronger localized surface plasmon resonance effect and higher absorption in the near-infrared(NIR) region, benefiting from the free-electron interaction enhancement between Au and ITO. The nonlinear optical properties were investigated using a modified femtosecond intensity-scan system, and the results demonstrated Au/ITO nanocomposite arrays with a remarkable two-photon absorption saturation effect for femtosecond pulses at 1030 nm. The versatile NIR optical responses indicate the great potential of the elaborately prepared 2D periodical Au/ITO nanocomposite arrays in many applications such as solar cells, photocatalysis,and novel nano optoelectronic devices.

Electric field enhancement of coupled plasmonic nanostructures for optical amplification

Plasmonic effects that enhance electric fields and amplify optical signals are crucial for improving the resolution of optical imaging systems. In this paper, a metal-based plasmonic nanostructure (MPN) is designed to increase the resolution of an optical imaging system by amplifying a specific signal while producing a plasmonic effect via a dipole nanoantenna (DN) and grating nanostructure (GN), which couple the electric field to be focused at the center of the unit cell. We confirmed that the MPN enhances electric fields 15 times more than the DN and GN, enabling the acquisition of finely resolved optical signals. The experiments confirmed that compared with the initial laser intensity, the MPN, which was fabricated by nanoimprint lithography, enhanced the optical signal of the laser by 2.24 times. Moreover, when the MPN was applied in two optical imaging systems, an indistinguishable signal that was similar to noise in original was distinguished by amplifying the optical signal as 106 times in functional near-infrared spectroscopy(fNIRS), and a specific wavelength was enhanced in fluorescence image. Thus, the incorporation of this nanostructure increased the utility of the collected data and could enhance optical signals in optics, bioimaging, and biology applications.

Automatic Measurement for Fabric Surface Shapes with Two-Dimen-sional Fourier Transform Profilometry

Two- dimensional Fourier transform profilometry (2 -D FTP) for data acquisition of fabric surface shapes isproposed. Phase unwrapping technique based on digitalweighted filter and reliability mask are employed. Ex-perimentai results of shape measurement for several fab-ric appearances are given. From the measured results, itis shown that this method can make up for not only thedisadvantage of the gray level image analysis which isonly suitable for simple structure and solid - pattern fab-ric, but also the low speed and high cost of laser dotscanning technique.

Fabrication of Micro -Optical Devices by a Femtosecond Laser

Femtosecond laser is a perfect laser source for materials processing when high accuracy and small structure size are required. Due to the ultra short interaction time and the high peak power, the process is generally characterized by the absence of heat diffusion and, consequently molten layers. Various induced structures have been observed in materials after the femtosecond laser irradiation. Here, we report on fabrication of micro-optical devices by the femtosecond laser. 1) formation of optical waveg...

Fabrication of ordered micro- and nano-scale patterns based on optical discs and nanoimprint

A simple method to fabricate one-dimensional(1-D) and two-dimensional(2-D) ordered micro- and nano-scale patterns is developed based on the original masters from optical discs, using nanoimprint technology and soft stamps. Polydimethylsiloxane(PDMS) was used to replicate the negative image of the 1-D grating pattern on the masters of CD-R, DVD-R and BD-R optical discs, respectively, and then the 1-D pattern on one of the PDMS stamps was transferred to a blank polycarbonate(PC) substrate by nanoimprint. The 2-D ordered patterns were fabricated by the second imprinting using another PDMS stamp. Different 2-D periodic patterns were obtained depending on the PDMS stamps and the angle between the two times of imprints. This method may provide a way for the fabrication of complex 2-D patterns using simple 1-D masters.

Development of Flexible Luminous Fabrics for Photodynamic Therapy in Biomedical Applications

Fabrics integrating with side-emitting polymer optical fiber( SE-POF) have great potentials for photodynamic therapy( PDT),which is a form of phototherapy recognized as a treatment strategy that is both minimally invasive and minimally toxic.Preliminary research has been undertaken to develop flexible luminous fabrics( FLF) device for PDT used in biomedical applications. The FLF device consists of SE-POFs, textile substrates,light source( LEDs or laser) with proper wavelength,and optical fiber coupling,etc. Different patterns of the fabrics were designed and fabricated purposely,and the light illumination effect was tested including the light power emitting from the patterned optical fiber fabrics,the stability of the illumination,and the light with different wavelengths. The work contributes to the successful development of an efficient and pain-alleviated illumination device for PDT in biomedical application.

Method for Detecting Fluff Quality of Fabric Surface Based on Support Vector Machine

In order to improve the accuracy of using visual methods to detect the quality of fluff fabrics,based on the previous research,this paper proposes a method of rapid classification detection using support vector machine(SVM).The fabric image is acquired by the principle of light-cut imaging,and the region of interest is extracted by the method of grayscale horizontal projection.The obtained coordinates of the upper edge of the fabric are decomposed into high frequency information and low frequency information by wavelet transform,and the high frequency information is used as a data set for training.After experimental comparison and analysis,the detection rate of the SVM method proposed in this paper is higher than the previously proposed back propagation(BP)neural network and particle swarm optimization BP(PSO-BP)neural network detection methods,and the accuracy rate can reach 99.41%,which can meet the needs of industrial testing.

全口径环形抛光的光学元件面形误差影响因素及其控制

全口径环形抛光是加工大口径平面光学元件的关键技术之一,其瓶颈问题是元件面形的高效高精度控制。通过研究元件面形的影响因素及其控制方法从而提升其确定性控制水平。围绕影响面形误差的运动速度、抛光盘表面形状误差和钝化状态等关键工艺因素,建立基于运动轨迹有效弧长的环形抛光运动学模型,揭示了抛光盘表面开槽槽型对面形误差的影响规律;提出了采用位移传感器以螺旋路径扫描抛光盘表面并通过插值算法生成其形状误差的方法,建立基于小工具的子口径修正方法,实现了抛光盘形状误差的在位定量修正;提出抛光盘表面钝化状态的监测方法,研究了抛光盘表面钝化状态对面形误差的影响规律。结果表明:抛光盘表面开槽采用环形槽时元件表面容易产生环带特征,采用径向槽、方形槽和螺旋槽时元件表面较为匀滑;通过在位定量检测和修正抛光盘形状误差,可显著提升元件的面形精度;随着抛光盘表面的逐渐钝化,元件面形逐渐恶化。在研制的5 m直径大口径环形抛光机床上加工800 mm×400 mm×100 mm平面元件的面形PV值优于λ/6(λ=632.8 nm),提升了元件的面形控制效率和精度。