High speed laser-assisted diamond turning of Tungsten carbide molds: an alternative to ultra-precision grinding

The OPTIMUS platform's laser-assisted technology has revolutionized ultra-precision diamond turning of tungsten carbide, employing a laser to enhance the diamond cutting tool's photon energy, thus minimizing mechanical energy dependence. This advancement builds on research into the tool rake angle's effect on cutting efficiency, exploring optimal rake angles combined with high laser power to maximize the Material Removal Rate (MRR). Preliminary findings indicate the ability to achieve a pre-polish ready optic with a 5 mm diameter aperture in just 20 minutes, significantly faster than the 2-3 hours required by traditional ultra-precision grinding, without compromising form irregularity and surface finish. Achieving an MRR nearly tenfold that of conventional methods, this technique represents a breakthrough for mass-producing tungsten carbide molds for glass optics. The study also provides a detailed comparison of the advantages and limitations of each technology, highlighting the potential of laser-assisted diamond turning in high-volume manufacturing settings.