Introduction: The Limits of Traditional Optical Cutting Methods
The demand for ultra-precise, damage-free optical components is rising across industries like 3D sensing, AR/VR, LiDAR, and biomedical imaging. The optical cutting technology becomes important.However, traditional cutting methods like laser и waterjet are struggling to meet the tolerances, cleanliness, and edge quality required in these applications.
Common optical materials include:
- Borofloat glass
- Fused silica
- Сапфир
- Polymer-coated glass
- Optical ceramics
All these materials are brittle, prone to thermal or mechanical damage, and often have delicate coatings or microstructures.
Comparison: Laser vs Waterjet vs Endless Diamond Wire
| Характеристика | Лазерная резка | Гидроабразивная резка | Бесконечная алмазная проволока |
|---|---|---|---|
| Heat Impact | High (100°C+) | low | low |
| Edge Chipping | От среднего до высокого | Средний | Very Low |
| Min. Feature Size | <100 μm (depends on lens) | >300 μm | <80 μm |
| Coating Compatibility | Poor (bubbling, delam) | Poor (water damage) | Превосходно |
| Surface Cleanliness | Soot or oxide residue | Wet, may leave salts | Clean (DI water rinse) |
| Расходные материалы | Laser tube, optics | Abrasive, nozzles | Wire (long life) |
| Техническое обслуживание | Высокий | От среднего до высокого | Низкий |
| Total Cut Quality | ★★☆☆☆ | ★★☆☆☆ | ★★★★☆ |
Technical Advantages of Endless Diamond Wire
🔹 Cold and Dry Cut
No heating or water contact. Ideal for laminated optics, coated layers, or materials with thermal sensitivity.
🔹 Precision and Repeatability
Wire positioning and speed are tightly controlled. Enables ±10 μm slicing repeatability across multi-batch production.
🔹 Gentle on Coatings and Layers
No delamination, micro-bubbling, or adhesive failure observed on:
- AR coatings
- Polymer-on-glass diffusers
- Optical filters
- Mirror stacks
🔹 Cleanroom-Compatible
No abrasive slurry or post-wash required. Output is clean and ready for direct bonding or coating.
Adoption Trend Across Industries
OEMs and fabs are transitioning to endless diamond wire saws, especially for:
- 3D sensing diffusers
- Micro-prisms
- Wafer-level optics
- Custom DOE and LIDAR lenses
Case studies show a yield improvement of 25–40% and a 50% drop in rework time compared to laser or waterjet setups.
Recommended Equipment for Modern Optical Cutting Technology
Vimfun’s lineup of endless diamond wire saws supports a wide range of optical cutting technology demands:
- SG 20 — Compact and precise, ideal for slicing thin optical wafers and coated glass substrates.
- SGR 20 — Optimized for straight, clean cuts in prisms and rectangular optics with minimal edge deformation.
- SGI 20 — Designed for 3D-profiled or structured optics, supporting multi-layer glass or irregular contours.
- SGRT 20 — Advanced cutting system with tilt and rotation axes for cutting at compound angles and non-planar geometries.
Each system integrates precision servo control, closed-loop tension feedback, and low-stress wire guidance—delivering the cutting edge of резка оптического стекла performance.
Conclusion: Endless Wire as the New Optical Cutting Standard
As the complexity and fragility of optical components increase, manufacturers are phasing out thermally aggressive or wet-cutting techniques.
Endless diamond wire offers unmatched balance of precision, edge quality, coating protection, and operational stability. It is fast becoming the preferred solution for clean, crack-free slicing of high-value optics.
