17
Jun
Driven by the rapid development of automotive optics, VR/AR, high-definition camera lenses and precision glass lenses, the industry has set stricter requirements on the profile accuracy, surface finish and service life of aspherical and free-form optical mold cores.
For two mainstream applications: glass molding and plastic optical injection molding, Moresuperhard leverages years of R&D experience in ultra-precision abrasives and cutting tools. We combine diamond wheel mirror grinding and SPDT (Single Point Diamond Turning) technologies, and provide customized abrasives as well as standardized processing solutions. Our products and services effectively solve industrial challenges including machining hard-to-cut materials, nano-level mirror finishing and high-precision machining of complex curved surfaces, enabling mass production of high-precision optical mold cores for manufacturers.
Main materials for optical mold cores are cemented carbide (WC-Co), silicon carbide (SiC) and steel substrates coated with high-phosphorus nickel-phosphorus (Ni-P) alloy, all featuring extreme hardness and high machining difficulty.
Strict industry standards: Profile accuracy PV ≤ 0.1 μm (≤ 0.05 μm for premium products), surface roughness Ra ≤ 5 nm (≤ 2 nm for ultra-high precision applications). No micro-cracks, scratches or pits are allowed on finished surfaces.
Tiny wear of grinding wheels or cutting tools, temperature fluctuation and machine vibration will directly lead to defective products. To address these pain points, Moresuperhard develops tailor-made solutions to balance ultra-high precision, production efficiency and overall cost.
This process is specially designed for hard cemented carbide and silicon carbide mold cores, widely used for high-temperature optical glass lenses and infrared optical components. Moresuperhard supplies a full range of custom diamond grinding wheels to achieve premium optical mirror surfaces.
We customize grinding wheels according to processing procedures, curved shapes and precision demands. High-quality diamond abrasives with narrow particle size distribution are adopted to prevent surface scratches:
Bond Selection: Resin bond (medium-soft grade) is the first choice for finish & mirror grinding, featuring excellent self-sharpening performance and low cutting force. 5%~10% micro-pores ensure smooth chip removal. Vitrified bond is ideal for rough and semi-finish grinding with outstanding high-temperature resistance and rigidity. Cast iron bond is applied for high-precision profile grinding, used with ELID (Electrolytic In-process Dressing) for superior shape retention.
Cup wheels for aspherical / concave cores, ball-nose wheels for free-form surfaces, straight wheels for datum planes. All wheels reach G0.4 ultra-precision dynamic balance grade with profile accuracy ≤ 0.001 mm. We also provide high-rigidity custom wheels for micro cores (diameter ≤ 5 mm).
Verified by mass production with φ10 mm cemented carbide cores:
Low-viscosity grinding oil (5~10 cSt) is adopted with filtration accuracy ≤ 1 μm. Working environment: Constant temperature 20±0.5℃, cleanliness Class 1000. All machines are equipped with air-floating vibration isolation platforms. Complete wheel dressing standards are formulated to maintain consistent precision during mass production.
Sintering of blanks → Multi-stage precision grinding → Full inspection → Pt-Ir / Iridium wear-resistant coating → Finished products.
Mold cores processed by Moresuperhard grinding wheels feature excellent high-temperature resistance and anti-adhesion performance, with greatly extended service life, perfectly matching high-end glass molding production lines.
For Ni-P coated mold cores applied in mobile phone lenses, VR/AR free-form surfaces and microlens arrays, Moresuperhard provides single crystal diamond turning solutions. Near-perfect nano-level optical surfaces can be formed in one pass without secondary polishing, greatly improving productivity.
We adopt premium natural single crystal diamond blanks with strict parameter control: Cutting edge radius ≤ 100 nm, nose radius R0.5~2 mm, optimized (111) crystal orientation for low friction and minimal burrs. Professional grinding and mist cooling prevent thermal damage, ensuring long tool life.
Matched with SPDT lathes with granite bed and air-bearing spindle. Production environment: Constant temperature ±0.1℃, constant humidity and high cleanliness to meet nano-machining requirements.
For micro-structure cores, fast tool servo system is available to enhance profile consistency.
CNC roughing of substrate → Electroless high-phosphorus Ni-P coating & stress relief → Rough & finish turning by single crystal diamond tools → (Optional) Bonnet polishing → DLC coating → Profile inspection & compensation → Delivery.
This streamlined process guarantees high yield rate and cost efficiency for mass production of small & medium-sized precision optical cores.
Moresuperhard supplies customized diamond grinding wheels and single crystal diamond tools, together with full technical support including process parameter optimization, on-site commissioning, wheel dressing and precision inspection guidance. We provide full services from product customization, process design, production line commissioning to after-sales technical maintenance.
Committed to ultra-precision optical machining, Moresuperhard helps optical manufacturers break precision limits, raise product yield and cut production costs with reliable products and standardized processes. We offer tailored solutions for both R&D samples and large-scale mass production.
We sincerely welcome global customers for sample testing, OEM customization and long-term cooperation!
