New Machines, Tools, and Processes for Modern Optics Manufacturing (with Demo Labs)

(40 person enrollment limit)

Dates: June 24-27, 2002 Registration: Monday at 8:00 a.m. Location: Center for Opto-Electronics and Imaging (COI) and Center for Optics Manufacturing (COM) South Campus University of Rochester Tuition fee: $1,150 if registering before 5/1/02; $1,250 if registering after 5/1/02 (full course notes provided)

New Machines, Tools and Processes for Modern Optics Manufacturing provides an extensive four day overview of the emerging technologies that will shape optics manufacturing in this century. Designed for those who must decide how to gain a competitive manufacturing advantage, the course is organized into 20 talks and tutorials that describe the new computer-aided machines and deterministic manufacturing processes that are redefining industry capabilities. New approaches and insights based on materials and manufacturing science are provided to improve classical optical fabrication and introduce new manufacturing concepts. Course topics include: evaluating polishing pitch, predicting rms surface roughness and subsurface damage depth, vibration analysis of CNC machines for optics manufacturing, and interferometric form metrology. Hear about the latest advances in diamond turning, the manufacture of polymer optics, and molding glass optics. Discover where optical tolerances come from, and learn how to recruit students into optical engineering careers. The program is very intensive and interactive, providing two full afternoons of demonstration laboratory sessions on CNC generation of aspheres and conformal optics, magnetorheological finishing (MRF), and modern optics metrology. Each participant receives a complete set of program notes. Advance registration is required; this course is available only as a four-day package. Registered attendees should report to the lobby of the Center for Opto-Electronics and Imaging, 240 East River Road (South Campus) on Monday morning, June 24, at 8:00 a.m.

Breakthrough Technologies for the Commercial Manufacture of Complex Optics

ALG 200 CNC Processing Center by Schneider Optikmaschinen GmbH & Co. KG

Q22-Y Magnetorheological Finishing (MRF) Machine by QED Technologies, Inc.

Twenty-six speakers and instructors will conduct the course

Julie Bentley (Ph.D., Rochester) Corning Tropel, Corp. Senior member technical staff and speaker Michael J. Cumbo (Ph.D., Rochester) RZ Optronics. CEO, speaker, and presenter Jessica DeGroote (B.S., Rochester) Center for Optics Manufacturing, University of Rochester. Ph.D. student and speaker Paul R. Dumas (M.S., Rochester) QED Technologies, Inc. Software manager and instructor Edward M. Fess (A.A.S., MCC) Center for Optics Manufacturing, University of Rochester. Senior technical associate and instructor Gregory W. Forbes (Ph.D., Australian National) QED Technologies, Inc. Senior scientist and instructor Paul D. Funkenbusch (Ph.D., Michigan Tech) Department of Mechanical Engineering, University of Rochester. Professor and speaker Birgit E. Gillman (B.S., RIT) Zygo, Corp. Production manager/SpectraFilm and speaker Donald Golini (M.S., Tufts) QED Technologies, Inc. Company president, optical engineer, and speaker Sheryl M. Gracewski (Ph.D., Berkeley) Department of Mechanical Engineering, University of Rochester. Professor, speaker, and instructor Leslie L. Gregg (A.A.S., MCC) Center for Optics Manufacturing, University of Rochester. Laboratory technician and instructor Stephen D. Jacobs (Ph.D., Rochester) Center for Optics Manufacturing / Laboratory for Laser Energetics, University of Rochester. Program organizer and speaker Irina Kozhinova (Ph.D., Kazan Inst. of Chemical Technology, Russia) Center for Optics Manufacturing, University of Rochester. Laboratory engineer and instructor Andrew Kulawiec (Ph.D., Rochester) Corning Tropel, Corp. Manager of component metrology and speaker John C. Lambropoulos (Ph.D., Harvard) Department of Mechanical Engineering, University of Rochester. Professor, speaker, and instructor Arne Lindquist (A.A.S., RIT) Schneider Optical Machines, LLC. General manager and speaker Daniel Malacara (Ph.D., Rochester) Centro de lnvestigaciones en Optica. Director of research, professor, and speaker Alexander Maltsev (Optical Polisher Certification, Kiev) Laboratory for Laser Energetics, University of Rochester. Master optician and instructor G. Michael Morris (Ph.D., CalTech) Corning RPC. CEO and speaker Harvey M. Pollicove (B.S., Rochester) Center for Optics Manufacturing, University of Rochester. Director and speaker Kathleen C. Richardson (Ph.D., Alfred) Schott Glass Technologies. Manager/R&D materials, speaker, and instructor Maria T. Robinson (M.S., Arizona) Zygo Corp. Customer support manager/eastern region, speaker, and instructor Henry J. Romanofsky (B.A., Rochester) Byelocorp Scientific Inc. Laboratory technician and instructor Jeffrey L. Ruckman (M.S., Illinois) Resultant Manufacturing Services. Manufacturing engineering consultant and speaker John Schaefer (M.S., Southern Illinois) Raytheon Elcan Texas. Product manager and speaker John Schoen (B.S., St. John Fisher College) Center for Optics Manufacturing, University of Rochester. Manager/development and engineering and speaker

Course Content and Manufacturing Technology Highlights - Days 1 and 2

6/24 Monday
Next generation optics manufacturing issues (Pollicove) - Ten years ago you couldn't buy computer-controlled optics manufacturing equipment. In the next ten years you won't be able to manufacture without it. Deterministic microgrinding of spheres, aspheres, and conformal parts (Ruckman) - Deterministic microgrinding is described, including the latest breakthroughs and current research for spherical, aspherical, and conformal optics. Chemical effects in classical optics fabrication (Cumbo) - New breakthroughs in understanding slurry charge effects can reduce agglomeration and produce smoother surfaces with classical polishing techniques. Lunch w/ speakers The world of optical testing (Malacara) - A brief description of all tests and techniques employed in the evaluation of optical systems, mainly optical surfaces. Special attention will be given to the evaluation of aspherical surfaces. Classical geometrical tests as well as interferometric tests will be described. Phase shifting techniques will be covered at a high level. Glass, glass making, and properties (Richardson) - Optical glass is defined by a review of its key optical properties and the methods for manufacture. The Optics Suitcase: demos to recruit students into optical engineering (Jacobs) - Take home theme packets that explore color with white light are used in middle school classrooms to excite students about careers in technology and optics. Learn how you can help in your own school district.

6/25 Tuesday
What mechanics and materials science can do for optics manufacturing (Lambropoulos) - The elastic (Young's modulus E), plastic (hardness H), and fracture (fracture toughness Kc) properties of brittle materials and simple micromechanics models may be applied toward understanding optics manufacturing phenomena such as loose and bonded abrasive microgrinding. These ideas allow us to predict the surface quality resulting from various optics manufacturing operations. How diamond tools work glass (Funkenbusch) - Characterization of tool surfaces and properties, as well as examination of the glass surface, can be used to understand the grinding process and to diagnose / trouble-shoot problems. Vibration analysis of CNC machines for optics manufacturing (Gracewski) - This presentation will provide an overview of vibration measurement techniques and discuss features on microground optical surfaces that are caused by vibrations. Lunch w/ speakers Afternoon Demonstration Labs #1 - Deterministic microgrinding (DMG) of spheres, aspheres, and conformal optics (Schoen, Fess, Gracewski) Ring tool DMG of spheres Contour tool DMG of aspheres Conformal optics Spindle vibration analysis Subsurface damage measurement #2 - Material science and classical optics fabrication (Cumbo, Richardson, Maltsev) Glass melting, annealing, and forming Glass microhardness and fracture toughness Grinding slurries and laps; polishing on pitch and polyurethane /20 parts from planetary or continuous polishers _____________________________ Evening Open

4:50 pm Center for Optics Manufacturing Reception and Open House Sponsored by Schneider Optical Machines for more information on COM, visit our website: www.opticsexcellence.org

Course Content and Manufacturing Technology Highlights - Days 3 and 4

6/26 Wednesday
Precision optics manufacturing for the future using magnetorheological finishing (MRF) (Golini) - State of the art MRF and its implementation on the shop floor will be described. Emphasis will be placed on turnkey solutions for affordable and reliable fabrication of high precision spheres and aspheres. Interferometric form metrology for precision machined surfaces (Kulawiec) - As form tolerances of precision machined surfaces become increasingly tighter, the need for advanced metrology methods becomes critical. Interferometric form metrology can supply the required accuracy, speed and flexibility for a variety of different applications. In this seminar, interferometric methods for the measurement of a number of different surfaces, including planes, cylinders, cones, toroids, spheres and aspheres, will be presented. Single point diamond turning (Schaefer) - This presentation will provide a comprehensive introduction and overview of single point diamond turning. Process details and capabilities will be described, including production strategies and applications for this rapidly maturing technology. Lunch w/ speakers Afternoon Demonstration Labs #3 - Modern optics metrology (Robinson) Interferometry with the Zygo GPI Microroughness with the Zygo NewView 5000 #4 - Magnetorheological finishing (MRF) (Kozhinova, Gregg, Romanofsky, Dumas, Forbes) Properties of magnetic fluids MRF machine testbeds Obtaining a polishing spot w/ MRF Using the MRF program for finishing Where do optical tolerances come from? (Bentley) - The origin and importance of optical tolerances required for manufacturing lens elements will be covered. Emphasis will be given to parameters such as radii, center thickness, surface irregularity, wedge, and centration. Manufacture of precision polyme r optics (Schoen) - Polymer optics provide unique benefits and solutions in optical systems applications. Polymer optics components and manufacturable design considerations will be presented. ___________________________ Wrap-up from 3:00-3:20 pm To register, please contact: Gayle Thompson University of Rochester, The Institute of Optics phone: 585-275-0056 e-mail: gayle@optics.rochester.edu

6/27 Thursday
Survey of comme rcial systems for optics manufacturing (Lindquist) - The demand for flexible, high precision manufacturing has produced a broad array of CNC controlled machine centers. This survey will introduce and discuss state-of-the-art spherical and aspherical optics manufacturing equipment and processes from one manufacturers perspective. Optical polishing pitch (Gillman/DeGroote) - Several aspects of optical polishing pitch will be discussed, including important pitch properties and how they are measured. Case studies will be used to illustrate common pitch problems and lessons learned in solving them. Diffractive- and micro-optics fabrication and applications (Morris) Fabrication methods to produce high performance diffractive- and microoptics components and subsystems are described. Several important application areas will be discussed, including laser printing systems, broadband imaging, head-mounted displays, novel anti-reflection surfaces, and polarization components. Lunch w/ speakers

5:30 pm - QED Technologies Open House