www.precitech.com

Global Manufacturer of Innovative Ultra Precision Machining Solutions

Solutions for the Automotive Industry...

Infrared optics applications

Headlamp optics molds

LED optics

Head-up display (HUD) molds

Low-cost imaging optics backup camera

Light detection and ranging (LiDAR) applications for self-driving cars

Pedestrian and animal detection

Signal lamp bezels and reflector molds

Precitech’s unique technologies enable many of the key ultra precision applications in the automotive industry.These include our high acceleration Fast Tool Servo (FTS) and high speed Levicron milling spindle used to create freeform shapes on headlamp optics molds.

If you are looking to manufacturer Head-Up Display (HUD) molds for automotive or aerospace applications, the Nanoform® 700 ultra or Nanoform® L 1000, are uniquely positioned to meet your needs. When equipped with an HD-160 spindle with a C axis and Adaptive Control Technology (ACT) there is no better solution in the market today for this application.

The HSK25 quick tool changing system from Levicron® and the Freeform® L 5-axis machine can be used to make corner cube molds for automotive signal lamp bezels and reflectors. Additionally, Precitech’s long history and knowledge of infrared manufacturing technologies enable such automotive IR applications as LiDAR systems for self-guiding cars, and pedestrian/animal detection.

Global Manufacturer of Innovative Ultra Precision Machining Solutions

Application: Headlamp Optics Molds

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: NiPSize: 65 x 55 mmShape: Concave asphere

Tool Details: Radius: 0.505 mmRake angle: 0°

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

ResultsMachining 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: GoodForm accuracy: < 1 µm PV

Setup photo

Enabling Technology – FTS Enabling Technology – Levicron Spindle

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.

Three Models FTS 1000 FTS 500 FTS 70

Travel 1000 µm ~~ 100 Hz 250 µm ~~ 200 Hz

500 µm ~~ 141 Hz 250 µm ~~ 200 Hz 62.5 µm ~~ 400 Hz

70 µm ~~ 100 Hz

Peak Acceleration 200 m/s2 200 m/s2 3000 m/s2

Typical Form <0.6 µm PV <0.3 µm PV <0.3 µm PV

Typical Finish <9 nm Sa <5 nm Sa <3 nm Sa

Servo Band Width 1000 Hz 1000 Hz 900 Hz

FastCom Control System

Operating System: Windows 7

DSP: Sharc ADSP

Typical position command update rate: 20 to 35 kHz

D to A converter: 18 bit, ultra-low-noise

Update time jitter: < 50 ns

GUI: Windows based UPx style

Two optional packages

Fiducial library – Programing objects defining the cutting path for frequently used fiducial (alignment) marks

20th order aspheric lens arrays with blend zones and on-the-fly tool compensation

Overview

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).

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

Key Specifications

Speed 60K, 80K, 90K, and 100K RPM options

Max Shaft Power 2.1 - 4.2 kW (2.8 - 5.6 hp) (configuration dependent)

Axial Stiffness up to 60 N/µm

Axial Load Capacity up to 550 N

Radial Stiffness up to 40 N/µm

Radial Load Capacity up to 330 N

Error motion Asynchronous error motions less than 30 nm axial

Global Manufacturer of Innovative Ultra Precision Machining Solutions

Goal: Demonstrate the surface finish and form accuracy achievable when machining a Head-Up Display (HUD) mold on either the Nanoform® 700 ultra or the Nanoform® L 1000 machine platform using Adaptive Control Technology (ACT) and an HD160 high capacity work holding spindle.

Process: Freeform XZC diamond turning with Adaptive Control Technology to eliminate errors in X and Y that repeat with spindle position

Part Details: • Material:

Brass

Process Details: • Tool: Single point diamond tool• Tool radius: 1.5 mm• Spindle speed: 200 rpm• Feed rate: 2.5 µm/rev• Coolant: Odorless mineral

spirits (OMS)

Results: • Surface finish near center:

0.744 nm Ra• Surface finish near edge:

1.31 nm Ra• Form error: 0.79 µm PV

Part Photo

Setup Photo

Sample 1- near center

Sample 1- outside edge

Status R.M.S. = 0.1127 ( µm) P-V = 0.7869 ( µm)

• Finishing pass duration: 176 min.• Z axis excursion: 1.5 mm

(twice per revolution)• Diagonal width: 192 mm

Application: Head-Up Display Mold

The stiffness and dampening of the HD-160 results in improved surface finish and the capacity for large parts and fixtures. The HD-160 has an ultimate load capacity of 170 kg (375 lbs.)

Precitech’s C axis and high resolution encoder, with feedback resolution of 0.010 arc-sec, and servo tuning algorithms allow for tight control of the rotary position of the spindle. The result is the capability to manufacture high accuracy freeform shapes with superior surface finish using XZC machining.

Finally, Adaptive Control Technology (ACT), exclusively offered by Precitech, utilizes a unique learning algorithm to eliminate errors in X and Z that repeat with spindle position. This allows you to increase the spindle speed, reducing manufacturing time while improving form error.

When equipped with an HD-160 spindle with a C axis and Adaptive Control Technology (ACT) there is no better solution in the market today for this application.

If you are looking to manufacture Head-up Display molds for automotive or aerospace applications, the Nanoform® 700 ultra or Nanoform® L 1000, are uniquely positioned to meet your needs.

Following error without ACT active

Following error with ACT active

Accommodate large and heavy parts HS 160 spindle

Manufacture non-rotationally symmetric freeform shapes Rotary C axis

Improve form and reduce machining time Adaptive Control Technology (ACT)

Key Machine Specifications Nanoform 700 ultra Nanoform L 1000

Swing capacity 700 mm (27.5 in.) dia. Max swing 1 m (39 in.) dia.

Surface finish < 1.0 nm Sa < 1.25 nm Sa

Form accuracy < 0.125 μm P-V < 0.125 μm P-V

Enabling Technologies: Large Frame Machines, High-Capacity Spindle, C Axis, and Adaptive Control Technology (ACT)

TalyMap Platinum 7.1.7288

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ISO 25178Height ParametersSa 1.4091 nm Arithmetic mean height

Sq 1.7790 nm Root-mean-square height

ISO 4287Amplitude parameters - Roughness profileRa 1.0969 nm Gaussian filter, 0.08 mm

Extracted profile

For demonstration purposes only!

TalyMap Platinum 7.1.7288

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ISO 25178Height ParametersSa 1.4091 nm Arithmetic mean height

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ISO 4287Amplitude parameters - Roughness profileRa 1.0969 nm Gaussian filter, 0.08 mm

Extracted profile

For demonstration purposes only!

Global Manufacturer of Innovative Ultra Precision Machining Solutions

Applications: Corner Cube Molds

Goal: Demonstrate a multi-tool milling process to machine a corner cube array and automotive reflector applications

Process: Freeform 4-Axis XYZC milling with HSK25 Quick Change Tooling System. The tools required to complete the machining process are mounted in individual tool holders. The balance quality and run-out of the tool holders allow them to be changed without having to redo the tool setting process.

Part Details: • Material: Aluminum

Tool Details: • Four carbide ball-end mills ranging from 0.3 to 0.75 mm in radius

to progressively deepen the corner cube pattern• One 0.3 mm radius diamond ball-end mill for finishing

Process Details: • Spindle Speed:

Four roughing passes 16,000 - 50,000 rpm (increasing each step) One finishing pass at 60,000 rpm

• Feed Rate: 200 mm/min

Machining Time: Four roughing passes 800 min. Total 2170 min.

Results: Optical quality surface and sharp corners on cube

Unable to find commercially available HSK25 tool holders appropriate for ultra precision machining, Levicron developed a

unique process to manufacture their own. They use their ultra precision spindles to grind the tool holders (see results below).

Enabling Technology – HSK25 Quick Tool Changing System from Levicron

Enabling Technology – Freeform® L 5-Axis Ultra Precision Machine

Applications: Ultrasonic assisted machining of steel mold inserts

Enabling Technology: Nanoform® X with son-x ultrasonic tool posts

UTS-x: Balance Quality G 0.3 mm/s at 60.000 rpm

Industry standard: G2.5 mm/s at 25.000 rpm

UTS-x: Static tool run-out < 0.8 μm TIR

Industry standard: 3 μm TIR

HSK quick change tool interface test at 180 mm from spindle front showing 0.5 μm run-out

Tool Change Repeatability Test by 4 x 90° Reversal Balanc-ing

• Industry leading swing and load capacity

• Flexibility to produce freeform geometries with 3 linear and up to 2 rotary CNC axes

• 5 Axis freedom with 3 axis performance Y axis and spindle designed for maximum thermal stability

• Thermally controlled enclosure options insure accuracy during long cutting-time parts

• Reduced sensitivity to vibration enabled by its integral TMC MaxDamp®

isolation system

• Capability to produce large and small parts auxiliary spindle mount to the X axis

• Insert tool in spindle • Cut test part • Correct tool radius, x center,

and tool height• Recut part, form = 0.15 μm • Remove tool and re-insert,

form = 0.1 μm• Remove tool and re-insert,

form = 0.12 μm

Key Specifications

Turning Surface roughness < 1.5 nm Sa performance Form accuracy < 0.125 μm P-V

Milling Surface roughness < 10 nm Sa performance (< 3 nm is achievable with optimum material & cutting conditions) Form accuracy < 0.2 μm P-V

Ultimate 91 kg (200 lbs.) @ 100 psi supply pressure load capacity

Standard swing 650 mm diameter over the B axis – can be expanded to 700 mm capacity when equipped with temperature controlled room

Precitech has added an innovative vertical axis to our field proven large frame platform, increasing flexibility and precision. With the Freeform L, customers can diamond turn, micro-mill, micro-grind, and groove non-rotationally symmetric surfaces. Adding this third linear axis gives users the flexibility to produce freeform surfaces which may not be achievable using 2 linear axis machining.

60 hour stability test using raster flycutting resulting in a 36 nm rms form error 50 mm x 50 mm Nickel Phosphorus)

Ultra Precision Machining with Automated HSP Tool Change

PV 0.154 µm

rms 0.036 µm

Removed: PST LST

Y Z turning test resulting in a 0.83 nm Ra surface finish

(Nickel Phosphorus)

Size X 0.7 mm

Size Y 0.5 mm

PV 9.156 nm

rms 1.054 nm

Ra 0.829 nm

+0.00507

µm

-0.00408

Material: hardened steel 52 HRC Diameter: 30 mm Depth: 7 mm Surface finish: 1.1 nm Ra Form accuracy: 61 nm PV

In many automotive molding applications it may be beneficial to use steel given its heat resistance and hardness. The Nanoform X with son-x ultrasonic tool post is capable of directly machining steel molds with a surface finish of less than 2 nm Ra and a form accuracy of less than 200 nm PV. Typically the extraordinary diamond tool wear experienced while cutting steel has made it difficult to use as a mold material. With the ultrasonic tool post tool wear is comparable to other non-ferrous metals.

The dove-tail slide design of the Nanoform X results in superior dynamic stiffness. This enables better surface finish with the son-x device compared to what is achievable on other diamond turning machines.

5.23.12.97

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Modified Profile 7/19/2016 4:22:54 PM15CVTORIC - 1 - P/9.200mm/LS Arc 7/19/2016 4:21:49 PM15CVTORIC - 14.1mm/Admin/pgi 1240

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www.precitech.com

Global Manufacturer of Innovative Ultra Precision Machining Solutions

Americas44 Blackbrook Road Keene, NH 03431 USA tel: 603-209-4617

China Part A1, A4 2nd Floor Building No.1 Plot Section, No.526 Fute 3rd Road East, Pilot Free Trade Zone 200131 Shanghai, China tel: +86 21 5868 5111

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Singapore Cairnhill Metrology Pte Ltd Tan Peng 5 Jalan Kilang Barat#07-05/06, Petro CentreSingapore 159349 tel: 65-6890-0041 www.cairnhill.com Taiwan Long Hong International Hightech Co., Ltd. Taiwantel: (886)2 2651-3618www.lhcint.com.tw

Malaysia Cairnhill Metrology Pte LtdTan Peng 5 Jalan Kilang Barat #07-05/06, Petro Centre Singapore 159349tel: 65-6890-0041 www.cairnhill.com

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