Integrated manufacturing of ultra-large optical lens array based on single point diamond turning

Based on single point diamond turning technology, this paper presents a new method of high-precision ultra-large optical lens array manufacturing. By sequentially turning each concave surface, slow servo turning of complex profiles is converted into multiple standard turning, which greatly improves the processing efficiency and accuracy, and the best accuracy of the concave turning is 0.02λRMS. The strategy of gradient curvature radius machining is adopted in convex surface forming, which greatly reduces the amount of material removal and decreases the processing time. Finally, the turning trajectory optimization is adopted to avoid tool interference in the finishing process of convex surface forming, which effectively ensures the accuracy of aperture and surface shape. In this paper, the method has been used for the first time to complete the integrated forming process of ultra-large optical lens array, which provides a solution for the application of new optical systems.