{"id":5662,"date":"2025-10-23T13:59:59","date_gmt":"2025-10-23T05:59:59","guid":{"rendered":"https:\/\/www.endlesswiresaw.com\/?p=5662"},"modified":"2025-10-28T14:44:25","modified_gmt":"2025-10-28T06:44:25","slug":"polymer-on-glass-diffuser-cutting","status":"publish","type":"post","link":"https:\/\/www.endlesswiresaw.com\/tr\/polymer-on-glass-diffuser-cutting\/","title":{"rendered":"Case Study: Low-Temperature Cutting of Polymer-on-Glass Optical Diffuser"},"content":{"rendered":"<p class=\"wp-block-paragraph\">VIMFUN demonstrates precision polymer-on-glass diffuser cutting using an endless diamond wire saw. The process maintains coating integrity under 30 \u00b0C, uses only water coolant, and delivers flawless optical edges for high-value micro-optics.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>1. Project Background<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The customer provided a <strong>VIAVI EDC-50 Polymer-on-Glass Engineered Diffuser<\/strong> (50 \u00d7 50 mm).<br>The diffuser consists of a <strong>Schott Borofloat 33 glass substrate<\/strong> coated with a micro-structured polymer layer.<br>It is widely used in laser beam shaping, 3D sensing, and medical optics, where both <strong>heat and mechanical stress sensitivity<\/strong> are critical.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The customer requested the diffuser to be precisely cut into <strong>12 mm diameter circular pieces<\/strong>, with the following strict process conditions:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The coated surface must <strong>not be pressed or deformed<\/strong>.<\/li>\n\n\n\n<li>Cutting temperature must stay <strong>below 40 \u00b0C<\/strong>.<\/li>\n\n\n\n<li><strong>Low-pressure coolant flow<\/strong> to prevent peeling.<\/li>\n\n\n\n<li><strong>No solvent-based coolant or cleaning agents<\/strong> allowed.<\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>2. Material Characteristics<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Microscopic observation revealed a highly regular <strong>3-D microlens array<\/strong> pattern that defines the diffuser\u2019s beam profile and uniformity.<br>The polymer layer thickness is approximately <strong>20\u2013200 \u00b5m<\/strong>, with a <strong>2 mm glass base<\/strong>.<br>Any thermal softening or compression can permanently damage the optical function.<\/p>\n\n\n\n<figure class=\"wp-block-gallery has-nested-images columns-default is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\">\n<figure class=\"wp-block-image size-large\"><img fetchpriority=\"high\" decoding=\"async\" width=\"934\" height=\"688\" data-id=\"5665\" src=\"https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting1.webp\" alt=\"polymer-on-glass diffuser cutting\" class=\"wp-image-5665\" title=\"Endless elmas tel testere makinesi, hassas kesim i\u00e7in m\u00fckemmel bir makine aletidir\" srcset=\"https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting1.webp 934w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting1-300x221.webp 300w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting1-768x566.webp 768w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting1-16x12.webp 16w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting1-600x442.webp 600w\" sizes=\"(max-width: 934px) 100vw, 934px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" width=\"942\" height=\"696\" data-id=\"5666\" src=\"https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting3.webp\" alt=\"polymer-on-glass diffuser cutting\" class=\"wp-image-5666\" title=\"Endless elmas tel testere makinesi, hassas kesim i\u00e7in m\u00fckemmel bir makine aletidir\" srcset=\"https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting3.webp 942w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting3-300x222.webp 300w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting3-768x567.webp 768w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting3-16x12.webp 16w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting3-600x443.webp 600w\" sizes=\"(max-width: 942px) 100vw, 942px\" \/><\/figure>\n<\/figure>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>3. Cutting Approach<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The cutting was performed using a <strong><a href=\"https:\/\/www.endlesswiresaw.com\/sg-20-glass-cutting-wire-saw\/\" target=\"_blank\" data-type=\"product\" data-id=\"2734\" rel=\"noreferrer noopener\">VIMFUN Endless Diamond Wire Saw<\/a><\/strong>.<br>To satisfy the \u201clow-temperature, solvent-free\u201d requirement, <strong>regular tap water<\/strong> was used as the cutting coolant after customer approval.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Main cutting parameters:<\/strong><\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th>Parameter<\/th><th>Value<\/th><th>Description<\/th><\/tr><\/thead><tbody><tr><td>Diamond wire diameter<\/td><td>0.30 mm<\/td><td>Endless closed-loop wire<\/td><\/tr><tr><td>Wire speed<\/td><td>50 m\/s<\/td><td>Continuous single-direction motion<\/td><\/tr><tr><td>Wire tension<\/td><td>90 N<\/td><td>Stable linear path<\/td><\/tr><tr><td>Feed rate<\/td><td>10\u201320 mm\/min<\/td><td>Heat-controlled cutting<\/td><\/tr><tr><td>Coolant<\/td><td>Tap water<\/td><td>Non-solvent, low-impact<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>4. Cutting Drawing &amp; Precision<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Cutting followed the customer\u2019s engineering drawing <\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Circular piece \u00d8 12 mm \u00b1 0.10 mm<\/li>\n\n\n\n<li>Total thickness 2.1 mm<\/li>\n\n\n\n<li>General tolerance per ISO 2768-1 fh<\/li>\n<\/ul>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<figure class=\"wp-block-image aligncenter size-full\"><img decoding=\"async\" width=\"748\" height=\"470\" src=\"https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting2.webp\" alt=\"polymer-on-glass diffuser cutting\" class=\"wp-image-5664\" title=\"Endless elmas tel testere makinesi, hassas kesim i\u00e7in m\u00fckemmel bir makine aletidir\" srcset=\"https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting2.webp 748w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting2-300x189.webp 300w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting2-18x12.webp 18w, https:\/\/www.endlesswiresaw.com\/wp-content\/uploads\/2025\/10\/Polymer-on-Glass-Cutting2-600x377.webp 600w\" sizes=\"(max-width: 748px) 100vw, 748px\" \/><\/figure>\n<\/blockquote>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>5. Results<\/strong><\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Dimensional accuracy:<\/strong> \u00b1 0.05 mm achieved.<\/li>\n\n\n\n<li><strong>Edge quality:<\/strong> Smooth cut, no chipping or melting.<\/li>\n\n\n\n<li><strong>Temperature:<\/strong> Remained below 30 \u00b0C during the process.<\/li>\n\n\n\n<li><strong>Coating integrity:<\/strong> No peeling, bubbling, or haze observed.<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">These results demonstrate that the <strong>VIMFUN Endless Diamond Wire Saw<\/strong> can reliably cut polymer-on-glass optical materials under low-temperature conditions while maintaining optical integrity.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>6. Conclusion<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">By optimizing wire speed, tension, and coolant control, VIMFUN successfully achieved precision cold-cutting of a polymer-coated optical diffuser.<br>This study confirms that:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>No solvent coolant is required.<\/li>\n\n\n\n<li>Regular tap water provides sufficient cooling efficiency.<\/li>\n\n\n\n<li>The coating remains completely undamaged.<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">This experiment provides a validated <strong>low-temperature cutting process<\/strong> for future work on similar <strong>polymer-coated optical components<\/strong> (such as EDC, DOE, and RPC series).<\/p>","protected":false},"excerpt":{"rendered":"<p>VIMFUN demonstrates precision polymer-on-glass diffuser cutting using an endless diamond wire saw. The process maintains coating integrity under 30 \u00b0C, uses only water coolant, and delivers flawless optical edges for high-value micro-optics. 1. Project Background The customer provided a VIAVI EDC-50 Polymer-on-Glass Engineered Diffuser (50 \u00d7 50 mm).The diffuser consists of a Schott Borofloat 33 [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":5666,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[451],"tags":[294],"class_list":["post-5662","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-customer-stories","tag-cutting-glass"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/posts\/5662","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/comments?post=5662"}],"version-history":[{"count":0,"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/posts\/5662\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/media\/5666"}],"wp:attachment":[{"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/media?parent=5662"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/categories?post=5662"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.endlesswiresaw.com\/tr\/wp-json\/wp\/v2\/tags?post=5662"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}