Introducción
Challenges in processing 3D-Coated Optical Lenses As AR/VR devices, automotive HUDs, and high-end imaging systems evolve, the demand for 3D-coated optical lenses has surged. These coatings — often multi-layer dielectric or functional films (such as ITO, SiO₂, or MgF₂) — are extremely sensitive to mechanical stress and thermal effects.
Traditional cutting methods, including grinding, reciprocating diamond wire, or laser cutting, frequently cause coating delamination, microcracks, or thermal damage, reducing yield and increasing polishing costs.
To address these challenges, Vimfun developed the Endless Diamond Wire cutting system, designed for precision optical applications. Its closed-loop endless structure ensures constant speed, stable tension, and uniform cooling — eliminating coating damage at the source.
Test Setup and Parameters
A controlled comparison test was conducted to evaluate Vimfun’s endless diamond wire in cutting 3D-coated optical lenses.
Material: 3D-coated optical glass lens (⌀30 mm, coating thickness ≈1.5 μm, multilayer dielectric film).
Equipment: Vimfun Endless Diamond Wire Cutting Machine (Model SGI20).
Cutting Parameters: wire speed 50m/s, feed rate 0.3 mm/min, tension 150 N, deionized water coolant.
Cutting request: protect the 3D layer do not damaged by heat or cutting force.
on-site photo of cutting setup
Test Results and Observations
Across multiple trials, Vimfun’s endless diamond wire demonstrated smooth, vibration-free cutting. The 3D coatings remained fully intact — no peeling, cracking, or surface scratches were observed.
Surface roughness and yield results:
| Parámetro | Reciprocating Wire | Vimfun Endless Wire | Improvement |
|---|---|---|---|
| Ra (μm) | 2 | 1.25 | ↑73% |
| Coating Integrity | 85% | 100% | ↑15% |
| Yield Rate | 90% | 99.5% | ↑9.5% |
microscopic picture of Vimfun cut edges
Microscopic analysis shows that the reciprocating cut samples exhibited minor coating chipping at the edges, while the Vimfun endless wire produced clean, continuous coating edges. Cutting debris was finer, chip removal was smoother, and surface gloss significantly improved.
Technical Explanation
Constant-Speed Endless Motion:
The endless wire eliminates reversal cycles. Speed fluctuation remains under ±0.3%, avoiding transient acceleration stresses that cause microcracks in coatings.
Stable Tension Control:
Precision servo tension control keeps uniform stress distribution along the wire, minimizing local stress concentrations — ideal for thin-film-coated substrates.
Cold Cutting Process:
Liquid cooling efficiently removes heat; the thermal-affected zone is nearly zero. Coating temperature rise stays below 3°C, maintaining film stability.
High-Precision Guide Wheel System:
Wheel runout ≤1 μm ensures smooth motion and minimal surface scratching, reducing post-polishing volume by over 30%.
Conclusion: A New Standard for Damage-Free Optical Cuttin
The test results confirm that Vimfun’s Endless Diamond Wire achieves truly “zero coating damage” in cutting 3D-coated optical lenses.
Its constant-speed, constant-tension, and cold-cutting technology significantly enhance surface quality and process reliability — making it ideal for:
AR/VR lenses and head-mounted optics
Automotive HUD optical modules
High-precision optical filters and windows
Multi-layer coated optical components
finished lens samples after cutting
Vimfun’s Endless Diamond Wire represents a step forward toward ultra-precise, low-loss, and high-yield optical manufacturing — setting a new benchmark for non-destructive material processing.
