A Novel Clamping–Cooling System for the Off-Axis Machining of Hydrophobic Micro-Optics
Source abstract
Abstract
The ultra-precision machining of micro-optics from low glass transition temperature (Tg) hydrophobic polymers is frequently compromised by thermal instability and kinematic constraints imposed by on-axis turning. To address these challenges, this study presents a novel clamping–cooling system engineered for the off-axis diamond turning of low-Tg polymers. The design integrates vacuum clamping for workpiece stabilization with an embedded microchannel network for efficient thermal management. Strategic material selection effectively balances thermal insulation with mechanical stability. Performance evaluations demonstrated robust thermal regulation: lens blank surface temperatures stabilized at 6 °C during stationary testing, and the system was able to drop below 0 °C under maximum cooling targets. This strict thermal control enabled achieving nanometer surface roughness. Ultimately, this modular system facilitates the scalable, simultaneous production of high-quality, polishing-free intraocular lenses (IOLs), advancing manufacturing capabilities for complex precision optics.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced optical system design · Advanced Surface Polishing Techniques · Nanofabrication and Lithography Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Laboratory for Precision Machining (LFM), Leibniz Institute for Materials Engineering (IWT), Badgasteiner Str. 3, 28359 Bremen, Germany
MAPEX Center for Materials and Processes, University of Bremen, Bibliothek Str. 1, 28359 Bremen, Germany
Advanced Medical Implant Consulting (AMIPLANT GmbH), Haidling 1, 91220 Schnaittach, Germany
Institute of Experimental Ophthalmology, Saarland University, Kirrberger Straße 100, 66421 Homburg/Saar, Germany
Funding
Bundesministerium für Forschung, Technologie und Raumfahrt
References (37)
Show source-provided references
1. Li, C. (2025). Editorial for Special Issue on Ultra-Precision Machining of Difficult-to-Machine Materials. Micromachines, 16.10.3390/mi16091004 ↗
2. A review of cutting tools for ultra-precision machining10.1080/10910344.2023.2180751 ↗
3. Ultra-precision diamond turning of optical silicon—A review10.1007/s00170-017-1529-x ↗
4. Review on cryogenic assisted micro-machining of soft polymer: An emphasis on molecular physics, chamber design, performance analysis and sustainability10.1016/j.jmapro.2022.06.035 ↗
5. Vacalebre, M., Frison, R., Corsaro, C., Neri, F., Santoro, A., Conoci, S., Anastasi, E., Curatolo, M.C., and Fazio, E. (2023). Current State of the Art and Next Generation of Materials for a Customized IntraOcular Lens according to a Patient-Specific Eye Power. Polymers, 15.10.3390/polym15061590 ↗
6. State of the art of intraocular lens manufacturing10.1007/s00170-018-2274-5 ↗
7. Cataract surgery practice patterns worldwide: A survey10.1136/bmjophth-2020-000464 ↗
8. Global Industry Analysts, Inc. (2024). Intraocular Lenses—Global Strategic Business Report, Global Industry Analysts Inc.
9. Individually Customized IOL Versus Standard Spherical Aberration-Correcting IOL10.3928/1081597X-20190814-02 ↗
10. Precision Deterministic Machining of Polymethyl Methacrylate by Single-Point Diamond Turning10.1080/10426914.2016.1140186 ↗
11. Mahajan, K., Pawade, R., and Balasubramaniam, R. (2021). Experimental Study of Effect of Machining Parameters on PMMA in Diamond Turning. Advances in Manufacturing Processes; Lecture Notes in Mechanical Engineering, Springer.10.1007/978-981-15-9117-4_2 ↗
12. Optimization of Process Parameters to Achieve Nano Level Surface Quality on Polycarbonate
13. Analysis of Surface Roughness and Waviness During Diamond Turning of Polycarbonate
14. Wang, W., Riemer, O., Rickens, K., Eppig, T., and Karpuschewski, B. (2024). Off-Axis Fast-tool-servo diamond turning of customized intraocular lenses from hydrophobic acrylic polymer. Proceedings of the 24th EUSPEN International Conference and Exhibition, Dublin, Ireland, 10–14 June 2024, EUSPEN.
15. (2024). Ophthalmic Implants—Intraocular Lenses—Part 2: Optical Properties and Test Methods (Standard No. ISO 11979-2:2024).
16. (2024). Ophthalmic Implants—Intraocular Lenses—Part 3: Mechanical Properties and Test Methods (Standard No. ISO 11979-3:2024).
17. (2021). Geometrical Product Specifications—Surface Texture: Areal—Part 2: Terms, Definitions and Surface Texture Parameters (Standard No. ISO 25178-2:2021).
18. Burr formation and control for polymers micro-milling: A case study with vortex tube cooling10.15446/dyna.v84n203.66095 ↗
19. A review of cryogenic cooling in machining processes10.1016/j.ijmachtools.2008.01.008 ↗
20. Experimental Investigation of Minimum Quantity Lubrication (MQL) as a Sustainable Cooling Technique10.1016/j.procir.2014.07.029 ↗
21. A review of the applications of phase change materials in cooling, heating and power generation in different temperature ranges10.1016/j.apenergy.2018.03.005 ↗
22. Microchannel cooling of concentrator photovoltaics: A review10.1016/j.rser.2018.04.010 ↗
23. Iyengar, M., and Garimella, S. (2006). Design and Optimization of Microchannel Cooling Systems. Proceedings of the Thermal and Thermomechanical Proceedings 10th Intersociety Conference on Phenomena in Electronics Systems, ITHERM, 30 May–2 June 2006, IEEE.10.1109/ITHERM.2006.1645322 ↗
24. A review on thermoelectric cooling technology and its applications10.1088/1757-899X/912/4/042004 ↗
25. Design and optimization of conformal cooling channels for injection molding: A review10.1007/s00170-019-04697-9 ↗
26. Cooling and dehumidification using vortex tube10.1016/j.applthermaleng.2017.05.015 ↗
27. Laser-Assisted Evaporative Cooling of Anions10.1103/PhysRevLett.123.103201 ↗
28. Williamson, R. (2011). Stresses Applied to Optical Components. Field Guide to Optical Fabrication, SPIE.10.1117/3.892101 ↗
29. Liquid nitrogen assisted-ice clamping strategy to suppress milling force-induced deformation and residual stress release deformation in thin-walled cylindrical shells10.1016/j.tws.2026.114488 ↗
30. Microclamping principles from the perspective of micrometrology—A review10.1016/j.precisioneng.2017.07.008 ↗
31. Influence of the arrangement of vacuum chuck holes on the transmittance wavefront of large-aperture KDP in single-point diamond turning10.1364/AO.382447 ↗
32. Baek, S.-W., and Yoon, K.-Y. (2019). Improving the Hybrid Electromagnetic Clamping System by Reducing the Leakage Flux and Enhancing the Effective Flux. Energies, 12.10.3390/en12193762 ↗
33. Borden, Y., and Inman, D. (2023, January 11–13). A Hybrid Piezoelectric-Hydraulic Actuator Model and Prototype with Large Stroke and Force Parameters. Proceedings of the ASME 2023 Conference on Smart Materials, Adaptive Structures and Intelligent Systems, Austin, TX, USA.10.1115/SMASIS2023-112125 ↗
34. Research on Axis Piezoelectric Six-Axis Force/Torque Sensor Clamping Device
35. Dynamics analysis for the clamping mechanisms of a rotary inchworm piezoelectric motor10.21595/jve.2016.16005 ↗
36. Development of Fixture Devices for Thin and Compliant Workpieces10.1016/S0007-8506(07)60114-0 ↗
37. Wang, W., Riemer, O., Rickens, K., Eppig, T., and Karpuschewski, B. (2024, January 1–4). Machinability of hydrophobic acrylic polymer for customized intraocular lenses. Proceedings of the 9th International Conference on Nanomanufacturing (nanoMan2024), Singapore.