A 3D Printed Grinder for Printed Lens Blanks

Fraens has developed a homebrew lens grinding machine that utilizes 3D printing for both the components and lens blanks. Contrary to common perceptions about 3D printing’s compatibility with optical components, this machine seeks to bridge the gap between a printed blank and a finished lens. The apparatus features a motorized chuck to secure the lens blank and an articulated arm holding the polishing tool, which has an eccentric drive for controlled movement. The lens grinding process involves the use of water and abrasive materials, and a large bowl is incorporated to collect swarf and maintain a clean work environment.

Lens blanks are printed using clear resin in an SLA printer, approximating their final dimensions. Fraens optimized the printing geometry, discovering that a 30° angle between the lens and the resin pool yielded the clearest blanks. To polish the rough blanks, a lapping tool made from polymer modeling clay is employed, capable of holding various pads and polishing compounds after being baked dry. The final steps involve running the blank through a series of abrasives to achieve the desired surface quality.

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