Large-scale fabrication of micro-lens array by novel end-fly-cutting-servo diamond machining

Zhiwei Zhu, Suet To, Shaojian Zhang

Research output: Journal article publicationJournal articleAcademic researchpeer-review

50 Citations (Scopus)


Fast/slow tool servo (FTS/STS) diamond turning is a very promising technique for the generation of micro-lens array (MLA). However, it is still a challenge to process MLA in large scale due to certain inherent limitations of this technique. In the present study, a novel ultraprecision diamond cutting method, as the end-fly-cutting-servo (EFCS) system, is adopted and investigated for large-scale generation of MLA. After a detailed discussion of the characteristic advantages for processing MLA, the optimal toolpath generation strategy for the EFCS is developed with consideration of the geometry and installation pose of the diamond tool. A typical aspheric MLA over a large area is experimentally fabricated, and the resulting form accuracy, surface micro-topography and machining efficiency are critically investigated. The result indicates that the MLA with homogeneous quality over the whole area is obtained. Besides, high machining efficiency, extremely small volume of control points for the toolpath, and optimal usage of system dynamics of the machine tool during the whole cutting can be simultaneously achieved.
Original languageEnglish
Pages (from-to)20593-20604
Number of pages12
JournalOptics Express
Issue number16
Publication statusPublished - 10 Aug 2015

ASJC Scopus subject areas

  • Atomic and Molecular Physics, and Optics

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