High-precision instruments often require larger optical lenses, specifically in the range of 100mm to 300mm in diameter, which are designed to manipulate and capture more light with exceptional accuracy, and are commonly used for applications like:
- Astronomy: These optics are used in telescopes for observing celestial objects. Larger apertures allow for better light collection and higher resolution images.
- Photography: Specialty telephoto lenses in this range capture distant subjects with clarity.
- Laser Systems: Precision optics are crucial for beam steering, focusing, and shaping in advanced laser systems used in research and industrial applications.
- Photolithography processes for semiconductor manufacturing, for precision patterning.
- Metrology and Machine Vision: Larger lenses are often used in instruments that measure profiles and features of objects, especially telecentric imaging where the size of the imaging field is set by the lens diameter.
Applications for Large Optics
Large optics play a role in various high tech and imaging applications due to their ability to collect more light, provide higher resolution, and cover larger fields of view. You often see them used more at the independent civilian level in applications like:
- Astronomy: Large optics are essential for astronomical telescopes, which require high angular resolution to observe dimmer celestial objects in space. The larger the optic, the higher aperture the optical system will have, allowing for clearer and more detailed images. Typically, telescopes and other instruments utilize optics up to 8 inches for more sensitive and better imaging. Some examples include earth observation satellites, infrared astronomy, exoplanet detection, space-based lidar systems and more.
- Scientific Research: Many universities are using large optics to advanced research in many fields such as advanced imaging systems, spectroscopy, quantum technologies and laser applications. By integrating large optics into their research programs, universities can push the boundaries of scientific knowledge and contribute to technological innovations.
Because of their specialty nature, varied applications, and a number of manufacturing challenges, these large optics are often small-volume, expensive and difficult to source. Very few of the major catalog optics providers carry 100mm to 300mm optics, so sourcing these components while ensuring quality standards has become an obstacle to research programs globally.
At Ross Optical, we provide one of the largest catalogs of large optics through our global vendor connections. Through our work with university research labs, microscopy and instrument companies, we have seen the many use-cases and challenges that come along with large optics, from manufacturing to sourcing.
Sourcing Challenges for 100mm to 300mm Optics
Much of the demand for 100mm to 300mm optics is from researchers who typically need one or a few optics, and face budget limits and timeline pressures that put custom optics out of reach. For these same reasons, there are very few catalog optics companies that carry optics in this diameter range. Ross Optical’s robust supply chain has allowed the company to carry 100mm to 300mm stock optics with lead times that meet most project demands.
Manufacturing Challenges for 100mm to 300mm Large Optics
Large optics manufacturing requires specialty equipment at every stage, a significant capital investment for inherently low-volume products. When working with a larger optical system, there are risks and higher costs that come from material sourcing and handling, special tooling, longer fabrication and polishing run times, and more. These challenges can significantly impact the overall efficiency and budget of a project. However, by understanding these potential pitfalls and planning accordingly, it is possible to mitigate these risks and achieve successful outcomes.
Cost Drivers for Large Optics
Manufacturing time: Larger size means they take up more space in the polishing machine and coating chamber, reducing the production rate per machine since they process as singles rather than multiples. Longer manufacturing run-time and lower yield contribute to the cost per optic.
Coatings: Large optics require special fixtures within the coater and may need additional in situ measurements to ensure uniformity. It’s important to find an optical coating house or supplier that can complete this process in-house to reduce the risk and cost of shipping between services and project times.
Environmental and Mechanical Sensitivities: When scaling an optical system up, environmental and mechanical sensitivities scale up as well. Issues that might be negligible in smaller systems can become major challenges in larger ones. For example, maintaining structural integrity becomes more difficult as the size increases, and gravitational sag can lead to misalignments or deformations in the optics. Because of this, the design and modeling process needs to be more thorough and advanced but also adds to the overall project costs.
Availability: The limited availability of large optics can drive up costs due to increased competition for these resources. When demand exceeds supply, prices tend to rise, making it more expensive to procure the necessary components. This can be particularly problematic if your project has tight budgets or requires a large number of optical components.
Optical Cleaning and Handling: Handling larger optics can become difficult, especially during the cleaning and packaging process. Keeping large optics clean and free from contaminants is important for overall performance. But cleaning large optics can be difficult due to their size and the need to avoid introducing any scratches or other damage during the cleaning process. They also require special packaging procedures for transporting to avoid any risks of scratches or breaking.
Quality Control and Metrology: An investment in specialty metrology equipment is required for appropriate quality control, typically a 4–6-inch interferometer and reference flat mirror up to 300mm aperture.
Considerations for Specifying and Sourcing Large Optics
Given the manufacturing and sourcing challenges for optics in 100mm to 300mm, it is important to be clear in your specifications and explore stock optics as a means of reducing lead time and cost.
Materials Selection
From visible glasses to calcium fluoride to fused silica, choosing the appropriate optical glass for your project is fundamental to achieving your desired outcome. The materials you select will significantly impact various aspects of your project. For example, the optical performance of the lens, including its clarity, resolution, and light transmission, is directly influenced by the material properties. Durability is another important factor since different materials offer varying levels of resistance to factors like temperature fluctuations, humidity and mechanical stress. Collaborate with an experienced supplier knowledgeable about these materials.
Fabrication
Large optics are typically run as singles, creating longer manufacturing times, which increases the overall costs.
We approach our work as a partnership with our customers by manufacturing and sourcing a significant stock of large optics that let us reduce your project costs. This is possible through our reliable, global supply chain and standardized components for specialized applications.
Optical Coating
Look to a single provider for fabrication and coating to reduce project risk, lead-time, and cost. Additionally, a large optic lens supplier should offer a full range of coatings, such as broadband, anti-reflection, single wavelength AR and other dielectric coatings. When working with a special coating, the production process is slower due to the limited space in standard coating machines.
Optical Metrology
Advanced optical metrology is necessary for large optics since they are often used as corrective lenses for high-precision imaging tools and telescopes. Without the appropriate testing processes, it becomes difficult to detect and correct minute deviations in the surface shape and quality of larger optics. This can lead to suboptimal performance and increased defect risks in the final product. Suppliers must have access to the right metrology tools and experience in developing a quality control process suited to large optics.
Sourcing with Ross Optical
Ross Optical addresses the challenge by manufacturing hard-to-find optical lenses that are critical for instruments like telescopes, imagers, and other precision devices. Our catalog includes one of the most diverse selections of standard large lenses, ranging from 100 mm to 300mm, reducing your cost per lens.
Through our global network, Ross sources achromats, plano convex lenses and other large optics to reduce supply chain risk and lead time. Additionally, we provide custom lenses and solutions to fit your project needs.
View our catalog today to find the perfect large optic for your needs.
