quality control

Accuracy and Consistent Control

Process Controls

Production Quality

Assured Conformance

Inspection Process

Process Controls

Our extremely accurate electroforms are a result of careful and precise control of all the vitally important plating parameters which can adversely affect the internal stress of plated deposits during the electroforming cycle. The advent of microprocessors has allowed Opti-Forms the most precise and consistent control of these parameters utilized in the industry today.

Our chemical lab Quality Control is responsible for maintaining process plating solutions.  We do this to identify and eliminate any possible contaminants while maintaining accurate chemical constituent balances. This allows the highest possible quality electroforms with an absolute minimum of residual stress. 

These precise process controls and our defined quality control procedures allow us to hold optical accuracies as close as +/- 30 arc seconds surface slope deviation from the master’s geometry. In addition, these precisely controlled plating parameters enable us to produce mirrors ranging in thickness from less than .005 to over .250 inches without any effect on the mirror's desired geometry.

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Quality Optics Production

Opti-Forms has the capability of producing a variety of specialized shapes including laser-pumping cavities, parabolic and elliptical 2-axis linear trough reflectors, ophthalmic molds, multi-faceted integrating reflectors as well as off-axis reflector segments.

Off-axis segments are produced by cutting from parent reflectors utilizing very precise electrical-discharge machining (EDM) technology. This unique and extremely accurate process eliminates optical distortions and dimensional deviations evident in conventional machining methods.

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Assured Conformance

Following the electroforming of a reflector, the part is carefully inspected (see our inspection process below) to assure conformance to all specifications. After post-processing, such as applications of coatings or electrical-discharge machining (EDM), all components are again fully inspected by our quality assurance department to verify product quality and accuracy consistent with all customer requirements.

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Inspection Process

Our visual inspection shall consist of the following items (where applicable):

  • Scratches
  • Digs
  • Sleeks
  • Surface Distortion
  • Stains
  • Contamination
  • Compressive Stress
  • Tensile Stress
  • Brightness Uniformity (coated reflectors only).

Definitions

Scratches – Thin shallow cuts or marks on an optical surface

Digs – Pits or small craters on the optical surface.

Sleeks – very fine (hairline) scratches.  Examples: caused primarily by cleaning or polishing the master tool or reflector.

Surface Distortion  (dings) – Indentations or deformations from either side of the reflector surface that cause irregularities or alterations in the reflected beam.  Examples: (1) ding in surface profile creates dark spots when viewing the beam image, (2) dings in inner diameter or outer diameter make the beam image out of round; concentric rings of the beam do not converge to a point (beam uniformity).

Brightness Uniformity - Distortion of the reflector can effect the image causing non uniform illumination.

Stains - Surface discoloration resulting from plating and cleaning processes.  Examples: stress, improperly fitted tooling or damaged tooling causing burning. 

Contamination - Dirt, smudges, cleaning residue and any other foreign substance not intended to be resident on the reflector or master tool. 

Visual Standards - Standards that are used to visually demonstrate acceptance and rejection criteria.  The standards may take the form of photographs, sketches, and/or actual hardware as applicable (EF substrates, coated or uncoated) (also known as limit standards).

Tensile Stress – The electrodeposited nickel during electroforming tends to contract or pull away from the mandrel at the edges.  This may cause curling or cracking.  It is also referred to as orange peel surface texture.

Compressive Stress – The electrodeposited nickel during electroforming tends to expand or become larger than the mandrel.  This may cause blistering or buckling.  It is also referred to as dimpling.

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PRECISION ELECTROFORMED OPTICS

• Low Cost Per Part - Exact Replicas

• MIL-O-13830 Compliant

• Optical Accuracy to ±2 Arc Minutes Slope

• Thickness Ranging 0.005 inch to 0.25 inch

Contact our engineering group for your next custom relfector project.

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