The Affordable Pre-Finishing of Silicon Carbide for Optical Applications

Creare proposes to develop a novel, laser-assisted, pre-finishing process for chemical vapor deposition (CVD) coated silicon-carbide ceramics. Our innovation will enable the affordable single-point turning of CVD silicon carbide from a near-net shape blank to a pre-finished aspheric optic. We will use our extensive experience and expertise in the advanced machining of ceramics to establish the parameter space for the production of high-quality, pre-finished aspheric optics from near-net shape blanks. Our innovation has a material removal rate (MRR) that is two orders of magnitude higher than current pre-finishing options including diamond grinding, ductile-regime machining, reactive atom plasma processing, or standard laser micromachining. In addition, our approach has demonstrated that these high MRRs can be achieved with no surface or sub-surface damage, which is key to minimizing the cost of the subsequent finishing operation. Our novel solution is readily integrated with existing or new ultra-precision machine tools. Thus, our innovation is effective, affordable, and flexible.