A Novel Clamping–Cooling System for the Off-Axis Machining of Hydrophobic Micro-Optics

Abstract

The ultra-precision machining of micro-optics from low glass transition temperature (Tg) hydrophobic polymers is frequently compromised by thermal instability and kinematic constraints imposed by on-axis turning. To address these challenges, this study presents a novel clamping–cooling system engineered for the off-axis diamond turning of low-Tg polymers. The design integrates vacuum clamping for workpiece stabilization with an embedded microchannel network for efficient thermal management. Strategic material selection effectively balances thermal insulation with mechanical stability. Performance evaluations demonstrated robust thermal regulation: lens blank surface temperatures stabilized at 6 °C during stationary testing, and the system was able to drop below 0 °C under maximum cooling targets. This strict thermal control enabled achieving nanometer surface roughness. Ultimately, this modular system facilitates the scalable, simultaneous production of high-quality, polishing-free intraocular lenses (IOLs), advancing manufacturing capabilities for complex precision optics.