Headlamp Optics molds

  • Application: Headlamp Optics Mold +


    Goal: Demonstrate high speed machining of a lens array on nickel plated steel

    Process: Use a Nanoform® X (Freeform L, Nanoform 700, or Nanoform L 1000) and Fast Tool Servo (FTS500) to machine an array of concave aspheres on an aspheric nickel plated steel mold for automotive headlamp optics molds

    FTS Details:
    Peak acceleration: 200 m/sec2
    Travel: 500 µm
    Typical form: < 0.3 µm PV
    Typical finish: < 5 nm Ra


    Part Details:
    Material: NiP
    Size: 65 x 55 mm
    Shape: Concave asphere


    Tool Details:
    Radius: 0.505 mm Rake angle: 0°

    Process Details:
    Spindle speed: 500 mm/min
    (constant surface speed)
    Feed per revolution: 4 µm/rev
    Coolant: OMS

    Results
    Machining Time: 3 hrs.
    Surface finish: 1.74 nm Ra
    (0.08 mm gaussian filter)
    Surface finish: 2.15 nm Rq
    (0.08 mm gaussian filter)
    Cosmetics: Good Form accuracy: < 1 µm PV
  • Enabling Technology - FTS +


    Precitech has more Fast Tool Servo (FTS) systems in use worldwide than any other supplier. Over the last 20 years Precitech has delivered over 500 FTS systems. FTS systems provide a rapid method to fabricate free form surfaces including: light management micro-structures, toric optics and mechanical features in contact lenses, lens arrays and laser collimators. FTS cutting is typically 10-15 times faster than other servo tool cutting methods (e.g. slow tool servo).

    Precitech FTS units can be added to all Precitech ultra-precision Nanoform and Freeform systems. FTS systems are controlled by Precitech's exclusive Fastcom III FTS fast command generator. The Fastcom III control is in two way communication with the main UPx control. Operators interact entirely with the UPx control while FTS programs are running. Fastcom is fully supported by Precitech DIFFSYS CAM software. Surfaces can be defined by mathematical expressions, by point clouds (up to 1,000,000 points) or by bitmaps. 


    Benefits of defining a surface by mathematical expression include:

    • No "point cloud" related limitations on the size of the surface or on the fine definition of individual features. 

    • Tool path commands are generated without interpolation between the lower resolution points in a point cloud rendering a more accurate surface.
  • Enabling Technology - Levicron Spindles +


    Levicron spindles are available in two configurations: ASD-Cx features a pneumatically operated collet system, and, the ASD-H25 features an industry standard, HSK25 interface, enabling the use of an off-the-shelf ultra precision solution for quick tool changes, saving time and money. Available in 60,000 and 80,000 rpm models, Levicron spindles permit faster manufacturing and a higher levels of quality than other spindles on the market. The low error motions, long and light shaft design, thermal stability, accurate quick tool changes, and robust bearing system allow for the quick chip-to-chip time and material removal rates required by highly productive industrial processes.

    Increase your productivity and reduce your tool expense up to 100,000 rpm and optional HSK25 quick change tool interface

    — quickly and repeatedly center a tool within 1 um and no balancing for small tools minimizes chip-to-chip time 
    — excels at rapid material removal due to high power and robust bearing design

    Improve your surface finish asynchronous error motion less than 30 nm Reduce your spindle soak time reaches thermal stability in under 5 minutes

    — radial growth limited by integrated symmetrical thin film cooling system 
    — axial growth limited by self compensating design (bearing cartridge growth in +Z offset by shaft growth in -Z)

    Accurately run at any speed shaft design ensure all natural frequencies are outside operating speed range 


    – no sweet spots



  • Automotive Industry Solutions Brochure +