1. Background: The Challenge of Cutting EDC-50 Diffusers
The VIAVI EDC-50 diffuser is a high-precision polymer-on-glass optical component used in laser beam homogenization systems across 3D sensing, imaging, and medical applications. With a dual-layer structure—Borofloat glass base and microstructured polymer coating—it poses extreme challenges in precision slicing.
Traditional methods failed due to:
- Laser cutting causing thermal damage and polymer delamination
- Waterjet cutting resulting in contamination and insufficient precision
- Mechanical methods producing cracks, coating peel-off, and poor edge quality
The customer faced high scrap rates and low process stability, unable to meet production standards.
2. Solution: SGI20 Vimfun Endless Diamond Wire Cutting Machine
Vimfun proposed its SGI20 endless diamond wire cutting machine, customized for brittle and sensitive multilayer optics. The key features applied:
- Cold cutting using deionized water, avoiding thermal stress
- Precision tension control to reduce local mechanical stress
- Stable closed-loop drive maintaining wire speed ±0.3%
- Fine wire optimized for edge fidelity and low Ra
(SGI20 setup and diffuser sample images)
3. Test Results and Process Improvement
Performance improvement was validated across a cutting test:
| Metric | Laser / Waterjet | SGI20 Endless Wire | Improvement |
|---|---|---|---|
| Coating Integrity | 65–75% | 98.7% | ↑30%+ |
| Edge Chipping | 10–15% | <0.5% | ↓95%+ |
| Surface Contamination | High | Minimal | — |
| Overall Yield | 70% | 99% | ↑29% |
The customer observed dramatic reduction in yield loss and rework time.
4. Conclusion: Ideal for Precision Polymer-Coated Optics
Vimfun’s SGI20 endless diamond wire system delivers a reliable, contamination-free, and low-stress cutting solution for EDC-50 and other 3D-coated optics.
It now supports full-scale production for polymer-on-glass diffusers, making it a key technology for manufacturers in:
- Optical sensing
- Laser systems
- Display and HUD modules
- Medical imaging optics
(close-up of finished edge + clean cut surface)
