Diamond Turning
Diamond Turning at Denali Vision
Single Point Diamond Turning (SPDT) is integral to nearly all our polymer optics programs. From prototyping and tooling inserts to pilot production, diamond turning is a fundamental part of our process, enabling us to meet the most demanding optical requirements.
Prototyping
Innovative Design Feasibility
Our diamond turning capabilities allow us to take on some of the most challenging optical elements with complex forms and shapes. Optical engineers frequently push the limits of manufacturability with innovative designs, and our diamond turning process helps bring these designs to life.
Performance Validation
Rapid prototyping through diamond turning provides a cost-effective way for engineers to test their optical designs within systems before making significant investments in tooling. This method allows for early detection of potential design issues, ensuring optimal performance.
Material Feasibility Testing
Uncertain if a polymer optic will perform as well as glass in your system? Diamond turning allows for the creation of prototypes to test and confirm performance, often proving that polymers are a viable alternative to glass.
Injection Molding Precision
While we excel in precision injection molding, diamond turning provides an additional level of accuracy. By diamond turning prototypes within the tolerance range of injection molding, we provide optical engineers with prototypes that mirror the tolerances of the final molded optics. This ensures that the optical systems can accommodate the necessary tolerance stack for molded optics.
In-House Mold Insert Fabrication
We diamond turn our optical mold surfaces in-house, ensuring complete control over form, surface roughness, and mechanical dimensions. This in-house capability guarantees that our molds meet the highest standards of quality and precision.
Error Compensation for Mold Inserts
During injection molding trials, polymers may not shrink uniformly, especially with freeform surfaces. By performing advanced form metrology, we can feed this data into our diamond turning machines to re-cut mold inserts and compensate for molding process errors. This results in molded optics that meet precise form specifications.
Optical Insert Maintenance
Our on-site equipment allows us to perform 100% cleanup cuts on old optical inserts, extending the life of transferred molds and ensuring continued high-quality production.
Bridging Production Gaps
Our pilot production services bridge the gap between injection mold build time and immediate market demand. This ensures that you can meet market needs while your full-scale production tooling is being prepared.
Market Testing
Pilot production allows for testing market acceptance prior to significant investment in tooling. This approach helps validate product demand and specifications before committing to large-scale production.
Tight Specification Production
When specifications are too tight for injection molding, our diamond turning process provides the precision needed to meet stringent requirements, ensuring that your optical elements perform flawlessly.
Our diamond turning capabilities are designed to provide the highest precision and quality for your optical elements.