Introduction: Precision Demands in 3D Sensing Optical Components
Vimfun endless diamond wire cutting create a new approach for 3D Sensing Optical Components.
The rapid expansion of 3D sensing technology in smartphones, AR/VR, facial recognition, and automotive systems has increased the demand for complex optical components—especially polymer-coated, microstructured glass substrates.
These substrates serve as beam shaping, light diffusing, or wavefront control elements, often integrating ultra-thin polymer films on borosilicate or fused silica. Typical characteristics:
- Film thickness: <2 μm
- Microstructure geometry: <10 μm pitch
- Material pairing: high refractive index contrast (e.g., polymer + glass)
- Thermal sensitivity: coating deformation >40°C
The challenge lies in precisely cutting these brittle-glass + soft-coating composites without degrading optical performance.
Limitations of Conventional Cutting Methods
🔹 Laser Cutting
- Induces local heating >150°C
- Causes polymer bubbling, delamination, or refractive index drift
- Leaves thermal stress marks and requires post-cleaning
🔹 Waterjet Cutting
- Difficult to achieve <±50 μm precision
- Water intrusion can damage structured surfaces
- Leaves contamination and necessitates long drying cycles
🔹 Mechanical Grinding / Reciprocating Wire
- Vibration-prone
- Leads to edge chipping and coating shear failure
- Cannot maintain coating continuity across cut edge
Solution: Endless Diamond Wire for Cold, Stable, and Clean Cutting
Vimfun’s endless diamond wire cutting system offers unique benefits for microstructured optics:
✅ Cold Cutting — No Thermal Deformation
- Uses deionized water as coolant
- Maintains polymer layer below 25°C
- Preserves microstructure fidelity and coating adhesion
✅ Zero-Vibration Drive
- Endless loop ensures no acceleration-reversal
- Eliminates micro-cracking and coating delamination
- Wire path deviation <±1 μm with precision guide system
✅ High Edge Quality
- Achieves Ra <0.15 μm, edge roughness ideal for optics
- No flaking or residual stress at glass-polymer interface
- Post-processing time reduced by 40–60%
Applications and Use Cases
Endless diamond wire is now widely used in slicing:
- Structured light diffusers in Face ID and ToF sensors
- Beam homogenizers for VCSEL arrays
- Custom diffractive optical elements (DOEs) in AR projection
- Micro-lens arrays with hybrid coatings
Compared to traditional systems, yield has improved from ~75% to >98% in verified customer case studies.
(sliced polymer-on-glass sample edge under microscope)
Conclusion: Enabling High-Yield 3D Sensing Optics Manufacturing
3D sensing pushes materials and processes to their precision limits. The unique multi-material structure of polymer-coated optics demands stress-free, residue-free, and precision edge-cutting.
Vimfun’s endless diamond wire system sets a new standard:
- Clean edges
- Minimal tool wear
- Repeatable micron-level slicing
- Fully compatible with mass production and automation
Manufacturers adopting this method benefit from:
- 30%+ yield improvement
- Reduced post-processing
- Scalability to thinner and more complex optical stacks
