Surface data availability

Typically, part program generation tools relies on the availability of analytic surface descriptions, e.g. Zemax. However, in many cases the free-form surface has not been designed by optical design software, or for confidentiality the customer does not wish to share the analytic description

CAD file preprocessor

Through a proprietary pre-preprocessor, Kaleido is able to generate part programs to nanometer accuracy from an IGES or STEP file describing a free-form surface profile, eliminating the need for analytic surface descriptions

Machining system limitations

Slow-slide turning of free-form surfaces is made possible by ultra-precise interaction between the physical axes of the machining system. To ensure optimum surface finish and shortest possible machining time, it is desirable to push the machining system parameters to the limit. On the other hand, exceeding any parameter limits will destroy the axes interaction often with detrimental results. Typically this is avoided by means of an in-situ look-ahead buffer that slows down the machining process, if a physical parameter violation is about to occur. However, this solution leads to unpredictable results in terms of surface finish and machining time

Surface pre-analysis tool

To ensure machining with the best possible parameters, Kaleido Technology has developed proprietary control software that will ensure optimum cutting parameters leads to machining parameters being fully deterministic and surface finish and machining time known prior to machining.

Surface smoothness

Unlike on-axis turning that only involves surface discretization in the radial direction, by slow-slide turning the surface is discretized in both the radial and tangential direction and typically much more rapidly varying. Typically the interpolation between discrete points on  the surface is linear, and this leads to a highly undesirable coherent interpolation noise which is detrimental to free-form imaging applications.

Non-linear surface interpolation

Kaleido has devised and implemented a proprietary interpolation scheme that ensures a very smooth discretization and as a consequence the free-form surface becomes extremly smooth and free of any coherent discretization noise.