Artikel Innolite GmbH

The new ILSONIC Monolithic is the worlds leading ultrasonic tooling system operating at up to 120 kHz. With the use of ultrasonic assisted ultraprecise diamond cutting, optical surface finish can be achieved in hardened steel for high performance mold inserts or even glass substrates and infrared materials. With its unique monolithic design the ILSONIC significantly differs from the competitor´s products in terms of long term stability and life time.

Ultrasonic Assisted Diamond Turning Of Steel

For the past five years Innolite has been using the ILSONIC Technology internally to diamond cut optical surfaces in steel for LED headlight mold inserts as a leading supplier in German automotive production. The new ILSONIC Monolithic has been developed based on this outstanding long term industrial experience for highest efficiency and longest lift time of the product.

Ultra Sonic Assisted Diamond Turning Of Glass

The new ILSONIC Monolithic allows for the ductile cutting of glass and ceramic substrates. Continuous surfaces as well as micro structures can be diamond turned without the need of post polishing.

Ultra-Precision Machining Center  | IL600

The IL600 is a four or optionally five axes ultra-precision machining center for high productivity optics manufacturing. The integrated NanoGrip zero-point clamping systems ensure for the world´s leading flexibility in diamond machining systems. The IL600 allows for turning and freeform generation of optics, ruling, fly-cutting and grinding. We offer a range of contact and non-contact sensors that fully integrate into the machine and the control system for advanced optics characterization.

Key Features

Overdrive

The Innolite Overdrive is an ultra-high dynamic free-form and micro structure generator for diamond turning. It uniquely combines the advantages of slow slide and fast tool turning for advanced diamond untrue machining. Its linear motor driven hydrostatic slide with a moving mass of only 3 kg compares to the damping and the stiffness of a standard ultra-precision axis ensuring superb surface finish compared to an aerostatic fast tool servo. However, the dynamic reaction force during high dynamic motion is significantly lower and corresponding achievable dynamics are much higher compared to conventional slow tool turning. In terms of control system integration, the Overdrive can be programmed as a standard CNC axis as well as with the Innolite DirectDrive 2D or Direct Drive 3D.

NanoGrip

Our NanoGrip zero-point clamping system interface allows for submicron repeatability in exchanging tools, sensors for in line metrology and work pieces with only a few seconds. It’s a fundamental feature for the leading-edge productivity of Innolite´s ultra-precision machines. Individual pallets with four index positions for rotating at 90° angular steps are the exchangeable interface for the chucks mounted and aligned at the spindle (for work piece exchange) and at the Z-slide (for tool and sensor exchange). Due to it´s robust design, turning operation of up to 5.000 rpm is supported on the spindle side. With a vacuum chuck adapter provided by Innolite, standard diamond turning functionality meets high productivity in next generation optical manufacturing.

Technical Specification

IL600 General

System Configuration: Ultra Precision 4 (5) axis CNC high dynamic ultra precision machining center

Processes: Turning, slow tool turning, fast tool turning, ruling, milling grinding, measuring

Machine Base: Natural granite base for superb accuracy

Vibration Isolation: Self leveling pneumatic isolation system (either passive or electronically controlled active leveling, option

Control System: Beckhoff CNC industrial standard high performance machine controller, Intel® CoreTM i7, Quad-Core

Programming resolution: 1 nm linear, (0.01 nanometer optional) , 0.0000001 ° rotary

Set Points per second: 3.000 (CNC), 10.000 (Direct Drive)

File Transfer: USB, EthernetWater ControlActive chiller, < 0.02 °C/ 2 h

Evacuation: Machining chamber air evacuation filter < 1 μm

Turning Performance: Form accuracy < 0.2 μm, surface roughness (Ra) < 3 nanometers

Work Piece Diameter: 600 mm

Tätigkeitsfelder

Auf dem gesamten Weg der Kunststoffoptik-Fertigung …

Die Innolite GmbH ist Ihr kompetenter Partner zur Herstellung von Kunststoff- und Metalloptiken. Auf dem Weg zu Ihrem marktreifen Produkt begleiten wir Sie bei der fertigungsgerechten Auslegung der Optik und stellen Prototypen für den Funktionsnachweis des optischen Systems her. Unsere Kernkompetenz liegt in der Auslegung und Herstellung des zugeschnittenen ultrapräzisen Abformwerkzeugs für Ihren Kunststoffspritzguss- oder Heißprägeprozess. Gerne fertigen wir auch Kleinserien in Ihrem Auftrag.  

… bieten wir technologische Breite bei gleichzeitig hoher Expertise …

Unser breites Technologiespektrum im Bereich der Optikfertigung erlaubt uns, Ihnen fertigungstechnisch eine effiziente und kostenoptimierte Lösung für Ihr Produkt aus einer Hand anzubieten. Eingebunden in ein Netzwerk von Kooperationspartnern aus der Optikfertigung sind wir dabei als Unternehmen in der Lage, das erforderliche Maß an Erfahrung in ihre Aufgabenstellung einzubringen und gleichzeitig ausreichend Raum für innovative Lösungen zu lassen. Flexibilität heißt dabei für uns die individuelle Anpassung unserer Vorgehensweise an ihre Fragestellung, sodass Zeitoptimierung, Kostenoptimierung und höchste Qualität auf ein Gesamtoptimum geführt werden.  

… durch kontinuierliche Innovation und Hightech-Standards.

Mit unserem Firmensitz am Fraunhofer Institut für Produktionstechnologie IPT in Aachen haben wir Zugriff auf die neuesten Technologien aus den Bereichen Maschinen- und Prozessentwicklung für die Optikfertigung. Unsere fortwährende Bemühung, das Zusammenspiel aus Design, Material, Prozess und finaler Funktion zu verstehen, bedeutet für Sie die bestmögliche Lösung Ihrer produktionstechnischen Fragestellung.  

Historie

  Die Innolite GmbH wurde im August 2008 aus dem Fraunhofer Institut für Produktionstechnologie gegründet. Initiales Kerngeschäft war und ist der ultrapräzise Formenbau für die Replikation von Kunststoffoptiken sowie die direkte Fertigung von Metalloptiken. 2009 sind erste erfolgreiche Projekte im Bereich des Kunststoffspritzprägens abgeschlossen worden. In enger Zusammenarbeit mit den Kooperationspartnern Arburg und dem IKV der RWTH Aachen konnte somit ein entscheidender Beitrag für unsere Kunden hinzugezogen werden. In 2010 folgte die fertigungstechnische Umsetzung eigener Optiken für die LED-Beleuchtung. Die Entwicklung und der Aufbau von Ultrapräzisionsmaschinen haben 2011 in der Innolite GmbH begonnen. Mit der Vorstellung der IL600 im Mai 2012 wurde dieses neue Standbein offiziell und gefestigt.

Innolite is consequently developing in line metrology solutions consisting of ultra-precision contact and non-contact sensors, their productive machine integration as well as corresponding software routines for user friendly application. The standardized use of such metrology is a key for “driving productivity in ultra-precision technology” to Innolite. We measure dimensions, surfaces and optical axes on our machines to reach highest quality standards

Technical Specification

Tactile Sensor

Measuring Task Dimensions

Measuring Directions 3 (x, y, z), tactile

Sensitivity 0,25 μm

Contact Force0,07 N

Chromatic Confocal Probe

Measuring Task Surface shape, surface orientation

Measuring directions 1 (z), non-contact

Distance Sensor / Focus10 mm

Measuring Range1000 μm

Resolution 26 nm

Acceptance angle`+/- 15° @ error < 0.5 μm

Rotary Alignment of Probe0°-90°

LVDT Scanning Probe

Measuring TaskSurface shape, surface orientation

Measuring Directions1 (z), tactile

Sensitivity25 nm

Contact Scanning Force1 mN

Autocollimator

Measuring Task

Optical axis of sphere

Focal distance200 mm, 300 mm

Objectives6 automated exchange

Resolution< 1 ” of optical axis

Wavelength532nm, 634nm

ILCAM is the programming platform for all Innolite diamond and center turning machines. It is designed to create high quality production jobs for advanced optics manufacturing, consisting of pre-machining data analysis, referencing routines, machining programs, measurement cycles for quality assurance and integrated quality documentation. It allows for conventional optics manufacturing, free-form and micro structure generation as well as for combined optical surfaces. Different from conventional CAD/CAM software the fully automated integration of optics characterization routines is of highest value during production. With its functional spectrum, ILCAM is a unique platform for ultra-precision machining.

The IL300 is the leading ultra-precision diamond turning machine for high productivity, high flexibility optics manufacturing. It was designed to “drive productivity in ultra-precision technology” with consequently integrated submicron accuracy zero-point clamping systems, a stainless-steel enclosure and a high dynamic light weight construction for advanced dynamics. Applications cover standard diamond turning, free-form and micro structure generation as well as diamond turning of steel and infrared materials with ultrasonic assistance (ILSONIC).

Also look at IlCentric.

Key Features

NanoGrip

Our NanoGrip zero-point clamping system interface allows for submicron repeatability in exchanging tools, sensors for in line metrology and work pieces with only a few seconds. It’s a fundamental feature for the leading-edge productivity of Innolite´s ultra-precision machines. Individual pallets with four index positions for rotating at 90° angular steps are the exchangeable interface for the chucks mounted and aligned at the spindle (for work piece exchange) and at the Z-slide (for tool and sensor exchange). Due to it´s robust design, turning operation of up to 5.000 rpm is supported on the spindle side. With a vacuum chuck adapter provided by Innolite, standard diamond turning functionality meets high productivity in next generation optical manufacturing.