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quality of its surface to be high A number of problems exist in the production of precision optical elements and ophthalmic optical elements The problems are further compounded, and aspheric elements are preferred to spherical ones The tolerance on the vertical sag (Figure 116) for ophthalmic lenses is 8 m and on the surface profile 4 m for a lens of a 70 mm diameter and a 60 mm radius For precision lenses, the corresponding tolerances are made so that they are one order of magnitude less Lenses have been manufactured out of plastics, glass, and thermal imaging materials Fig 115: A single aspheric lens can function equisilicon and germanium [12] Surfaces on valently to three spherical lenses but is difficult plastics are produced by replicating them on to manufacture glass moulds which, in turn, are replicated by using ceramic moulds (rationally nonsymmetrical lenses) or (for rationally symmetrical lenses) on appropriate aspheric generators Ceramic mould surfaces have been generated on CNC milling machines, and rationally symmetrical glass
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Fig 116: The minute difference in the vertical sag of the spherical and the aspherical portions at the central part
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of a spectacle lens illustrates the difficulty in making aspherical (progressive) ophthalmic spectacles [13]
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lenses have been generated on both 4-axis and 5-axis CNC machining centres using metal-bonded as well as resinoid-bonded cup grinding wheels Aspherical and spherical surfaces Aspherical elements have the advantage of overcoming off-axis coma and aberration, which in the case of spherical elements is corrected by increasing their numbers A single aspherical lens can replace three spherical lenses [14] as shown in Figure 115 The maximum sag (difference) between an aspherical surface and a spherical one on a 70 mm blank having a radius of 60 mm shown in Figure 116 is 1058 m It is extremely difficult to maintain the small difference ranging from 0 at the bottom to 6 m within a diameter of 20 mm in the central and crucial region, which makes aspherical lenses to be more expensive compared to spherical ones Manufacture of aspherical plastic and glass lenses The classical replication technique [14], shown in Figure 117, is one method of manufacturing plastic lenses using glass moulds to form the lens The method used is the classical replication technique [14] shown in Figure 117 but this can be modified in their set-up for the mass manufacture of ophthalmic lenses During polymerisation, there is 14% shrinkage of the plastic material To accommodate the dimensional shape, the mould consists of two pieces forming the front and back
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Fig 117:
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An optical jacket used for making plastic lenses [14]
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surfaces of the lens These pieces are held together with a pliable gasket material For typical ophthalmic lenses, the mould surfaces are spherical or toroidal in shape and are readily made using conventional methods, which are known to be quick and inexpensive Manufacture of aspherical glass lenses The first step in the manufacture of aspherical lenses involves the fabrication of glass moulds by grinding (Aspherical generator) The manufacture of a glass mould from a ceramic mould using the sagging method is a time-consuming procedure and can sometimes take as long as an hour Also, as these ceramic moulds are fragile, they can break easily when handled Glass, silicon and germanium moulds have been manufactured by fine grinding on a CNC 4-axis machining centre and then polished [12] There is a wide variety of ophthalmic lenses that are available In humans who require spectacles, it is seen that very rarely is the power of one eye the same as the other The automation of assembly gaskets containing the inner and outer glass moulds for making lenses, which are discrepant, has been very successfully achieved Optical flat An optical flat (Figure 118) can be categorized as a precision product and is basically a highly polished piece of material such as a plate glass, optical glass, Pyrex or fused quartz Although quartz is the most expensive among the aforementioned materials, it is the best optical material known Optical flats are cylinders with a thickness varying from 3/ 8 to 3/4 inches (953 to 19 mm) and their diameter can vary from about 2 to 4 inches (508 to 1016 mm) [15] One of the circular surfaces of an optical flat is often polished so perfectly that its surface waviness or irregularity is virtually immeasurable However, optical flats can be manufactured in such a way that both their circular surfaces are flat and Fig 118: An optical flat [15] perfectly parallel to each other By using optical flats, a simple and rapid checking of the flatness of surfaces has been done very accurately
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