Technical Brochure

Machining Capabilities
• Single-point diamond turning.
• Hard turning.
• Precision grinding.
• Ductile-regime grinding (brittle materials).
• Micro-milling.
• Flycutting.
• “Slow-tool servo” capabilities for the
• manufacture of non-axisymmetric/freeform
• components.
• On- and off-machine gauging and toolpath
• correction.

Ultra-Precision Components
OPI’s Ultra-Precision Machining and Diamond Turning Services are helping R&D and production teams in aeronautics and space, consumer goods, defense, bio-medical, and automotive industries create ultra-precision components, including: 

• Transmissive and reflective optics. Example >
• Spherical, aspherical, non-axisymmetric, and prismatic components.
• Lens and mirror molds (e.g., cameras, projectors, scanners).
• Semiconductor and electronic components.
• Projection lithography lens cells and spacers.
• Micro components (e.g., magnetic heads, MEMS).
• Optical system prototype components—including mounting structures.
• Conformal domes and windows. Example >
• Precision munitions. Example >
• Diffractive and hybrid (e.g., refractive/diffractive) surfaces.
• Prosthetic orthopedic joints. Example >
• Engineered surfaces.

Created with cutting-edge diamond-turning technology and both commercial and purpose-built metrology equipment, OPI-manufactured components can be delivered with sub-micrometer figure accuracies and sub-nanometer finishes.

Development Services
Product and Process Development. OPI specializes in process and manufacturing system development and is able to cost-effectively produce components in low volumes. Working in our own cutting-edge facility, OPI engineers and technicians will manufacture prototype components and develop production processes to your specifications–without disturbing your production operations. Design and manufacturing specifications (cutting speeds, required tools and fluids, error correction, etc.) are well-documented to facilitate the establishment of final production protocols.

Metrology. OPI’s staff is expert in dimensional metrology at the cutting edge and uses state-of-the-art equipment, including the OPI 150 SCMM, to certify the final product and, in some cases, control the manufacturing process. Other OPI metrology equipment includes a Form Talysurf, Moore measuring machine, Zygo NewView, Talystep, laser interferometer, reference artifacts, and microscopes.

Experience. Dave Youden and Dan Thompson lead a staff of precision engineers dedicated to ultra-precision engineering and manufacturing. They offer a combined 70+ years of experience that includes senior positions in Fortune 100 companies and leading R&D laboratories. Recognized with numerous awards from industry associations, both are past presidents of ASPE, and widely published in the areas of precision engineering, deterministic manufacturing, metrology, and machine tool design and testing.

Materials
OPI machines a wide range of materials including:

• Metals: Aluminum, electroless nickel, electroplated nickel (High phosphorous content), brass,
• copper, gold, lead, silver.

• Crystals: Silicon, germanium, zinc sulfide, zinc selanide.

• Plastics: Acrylic, polystyrene, polycarbonate, PMMA.

In addition, OPI can hard turn, grind, and mill many other materials. Examples include: Steel, titanium and alloys, carbides, tungsten, tantalum, cobalt chrome alloys, glasses (ductile regime grinding), ceramics, cermets, ALON, spinel.