TECHNOLOGY
Five-axis ultra-precision machining, freeforms, ultrasonic-assisted diamond machining and integrated measurement. We combine the platform’s capabilities into a process suited to the material, optical function and inspection requirements.
OUR MACHINING CAPABILITIES
Diamond turning and freeform machining, Overdrive microstructuring, ultrasonic assistance, milling, grinding and integrated measurement.
The platform combines complementary processes for demanding components. We select the route to suit the material, geometry and intended function.
Discuss your component ↗MANUFACTURER REFERENCE DATA · IL600
| Characteristic | Manufacturer figure | Interpretation |
|---|---|---|
| Workpiece diameter | 600 mm | Geometry, workholding and tool access must be checked for each part. |
| Linear travel | X 600 · Z 400 · Y 250 mm | Axis travel does not define an unrestricted machining envelope. |
| Linear programming resolution | 1 nm | Control resolution; not finished-part accuracy. |
| Turning form accuracy | < 0.1 μm | Manufacturer reference; material- and process-dependent. |
| Surface roughness (Ra) | < 1.5 nm | Manufacturer turning reference; not a universal guarantee. |
FILM · YOUTUBE
OUR ENGINEERING ADVANTAGES
Our strength is connecting the right process, workholding and inspection for your application.
NanoGrip · modular workholding
Tools, sensors and workpieces share a zero-point interface. This supports repeatable setup and efficient transitions between operations.
Less realignment work between prototypes and variants.
Overdrive · five axes
We match dynamic tool motion to the surface geometry. Freeform optics, microlens arrays and local microstructures can become part of the manufacturing plan.
More design freedom when shaping optical performance.
ILSONIC · ultrasonic-assisted diamond machining
Ultrasonic tool motion helps control the interaction between the material and the diamond edge. We develop trial processes for hardened-steel optical inserts and selected glass or brittle-material tasks.
Material selection and optical finish can be developed together.
Turning · milling · grinding
We coordinate preparatory and finishing operations on the IL600 platform. Tool selection, access and workholding are planned around both optical and mechanical features.
One coordinated engineering approach to a complex component.
Integrated sensors · surface analysis
We connect contact and non-contact inspection with machining. Surface data, datums and deviation maps inform any corrective pass; final acceptance inspection is defined separately.
The next iteration can be based on measured evidence.
Temperature control · machine enclosure
Controlled cooling and enclosure air conditioning help limit the influence of temperature changes. Stabilisation and machining conditions are planned for the task.
A more consistent starting point for longer cuts and comparable trials.
We agree the achievable finish, inspection method and delivery plan for the specific material and geometry.
Discuss your componentIL600 · INSIDE THE PROCESS
Define the function, choose the process and agree the evidence before manufacturing.
B-AXIS · TOOL ACCESS
The B-axis adjusts tool orientation relative to a curved surface. This offers additional process routes for steeper profiles, dome-like geometries and raster operations. Workholding and available motion are reviewed against the complete geometry.
Value: tool access becomes part of toolpath planning.Surface slope, tool radius, clearance and sensor access.
Your next stepDiscuss a complex surfaceOVERDRIVE · FREEFORMS
Angularly varying profiles and local microstructures require dynamic tool motion. Overdrive coordinates this motion with the machining path. For off-axis optics and structured surfaces, we assess motion demands alongside the geometry.
Value: design choices extend beyond rotationally symmetric surfaces.Surface model, excursion, local curvature, structure pitch and permissible profile error.
Your next stepDiscuss freeform machiningMEASUREMENT · CORRECTION
Integrated contact and non-contact sensors support setup and intermediate checks. Before correction, we define alignment, datums and which deviations machining can address. Final acceptance remains a separate, agreed inspection step.
Value: trial-part data informs the next manufacturing decision.Evaluation aperture, coordinate system, form fitting, measurement method and correction allowance.
Your next stepDiscuss measurement and correctionMachine capabilities support process selection. Achievable component tolerances, surface quality and acceptance methods are agreed for the specific material and geometry.
PROCESS SELECTION
Our configured technology is a starting point. We agree achievable results for the specific material, geometry and inspection conditions.
Flat, spherical, aspheric and rotationally symmetric surfaces
Optical surfaces and mechanical datums in one manufacturing plan.
Form error, active aperture, surface and datums.
Freeforms, off-axis surfaces and microstructures
Machining angularly dependent surface profiles and local structures.
Tool access, surface slope and path dynamics.
Selected steel, glass and brittle-material tasks
An additional process route for more challenging materials.
Material grade, hardness, edge damage and a machining trial.
Local structures, grooves and datum surfaces
Coordinated operations for an individual component.
Tool radius, structure pitch, material and access.
Contact / non-contact feedback and workholding
Connecting setup, machining and correction.
Measurement method, realignment, datums and final inspection.
Aluminium, copper and nickel-based coatings: process selection depends on alloy, heat treatment and coating thickness. Substrate and optical layer are separate decisions.
Polymer type, residual stress and workholding matter. For replication inserts, tool surface and the subsequent forming process must be considered together.
Crystal orientation, edge quality and subsurface damage require attention. A targeted sample trial precedes the full geometry for a new material grade.
ENGINEERING IN DETAIL
For a rotationally symmetric asphere, tool movement and workpiece rotation together produce the required profile. In a freeform surface, height also varies with angular position, requiring coordinated axis movement. For microstructures, the local profile, edges and repeating features are requirements in their own right, alongside the overall form.
The design review therefore records the mathematical surface definition, coordinate system and functional aperture. Any discrepancy between the drawing and model must be resolved before manufacturing begins.
Innolite’s Overdrive system combines aspects of slow-slide and fast-tool turning. Its hydrostatically guided, linear-motor-driven axis supports rapid local movements. The manufacturer presents it for freeform surfaces and microstructures.
We evaluate surface shape, spatial frequency of variation, tool access and permissible machining marks when selecting a route. These factors determine the toolpath and any trials required.
Ultrasonic assistance adds high-frequency vibration to tool movement. Innolite’s ILSONIC presentation highlights optical surface machining of hardened steels and machining options for glass substrates. The manufacturer also uses the process for LED-headlamp tool inserts.
This is particularly relevant when tool-material wear resistance or thermal requirements make direct machining an alternative to a coated solution. Trial parameters are selected for the material grade, hardness, geometry and required surface.
The NanoGrip interface supports the exchange of workpieces, tools and measuring units within a common clamping system. Its value lies in coordinating machining and measurement operations.
Workholding design considers thin walls, distortion, orientation and access. Repeatable repositioning does not replace component inspection: critical datums and any need for realignment remain part of the process.
For metal optics, the substrate, heat-treatment condition and any nickel-based layer together determine the machining route. Polymer optics require different workholding and handling from rigid metal inserts. Crystals and brittle materials may also require assessment of orientation, edge damage and subsurface damage.
For the first discussion, we ask for the precise material designation and condition. Where only the function is defined, we compare possible material–process combinations and design a sample trial around the critical question.
Integrated contact and non-contact sensors support setup and in-process feedback. Final conformity requires the agreed characteristic to be checked using a suitable measurement and evaluation method.
Form deviation, local topography, datum positions and optical performance are different measurement questions. We retain the coordinate system, aperture, filtering and test conditions so that successive iterations can be compared.
PREPARE YOUR ENQUIRY
A drawing is useful, but so are a clear question and agreed inspection criteria. Start with a non-confidential summary; sensitive files follow an agreed secure process.
CONNECTED ENGINEERING
Conceptual illustration of our engineering approach.
THE NEXT STEP
Tell us about its function, material and critical engineering question. Together, we can define a feasibility review or a focused first trial.
