Manufacturing Process Category
CNC Numerical Forming
Precision CNC grinding and contouring for complex optical geometries -- inner cut-outs, multi-level steps, and freeform 3D surfaces. ISO 9001:2015 certified processes with 100% dimensional inspection.
Three Core Forming Processes
Engineers rely on tolerance specs, not marketing adjectives. Each process card below includes verified Technical Limits from our production data.
Inner Cut-outs & Drilling
Specialized in micro-holes and complex internal cut-outs for sensors, cameras, and embedded hardware components.
Technical Limits
- Min. Hole Diameter < 0.3 mm
- Positional Tolerance ±0.05 mm
- Min. Wall Thickness 0.4 mm
- Edge Chipping (max) ≤ 0.03 mm
Step Glass Processing
Multi-level CNC steps designed for IP68-rated seamless bonding with magnesium or plastic frames in ruggedized environments.
Technical Limits
- Min. Step Width 0.5 mm
- Step Height Tolerance ±0.02 mm
- Flatness (step face) ≤ 0.01 mm
- Max. Step Levels 3 levels
Irregular 3D Contouring
5-axis synchronous grinding for automotive displays and ergonomic wearable glass with compound curvature profiles.
Technical Limits
- Surface Roughness (Ra) < 0.2 μm
- Profile Tolerance ±0.03 mm
- Min. Contour Radius R 0.3 mm
- Axis Synchronization 5-axis CNC
We Solve Design Conflicts Before Mass Production.
"A perfect CAD drawing doesn't always yield a perfect product. We bridge the gap between aesthetics and manufacturability."
Common Yield Killer: Stress Concentration
Sharp internal corners create micro-crack initiation points during thermal cycling, leading to catastrophic yield loss in high-volume production.
Sharp Corner (0° radius)
Stress concentration at corner
R-Angle ≥ 0.2 mm
Stress distributed evenly
* Based on high-alumina glass inner cut-out production batch, n=5,000 pcs.
Winson Optimization: Tool-Path Refinement
By adjusting the feed rate at the exit point, we eliminate the 'chipping' issue common in high-alumina substrates -- verified via 50× micro-scan post-process.
"Iris's team reduced our prototype scrap rate from 22% to 3% through one simple edge modification."
-- Medical Device OEM, GermanyMaterial-Specific Parameter Libraries
Machining difficulty directly correlates with tooling cost and lead time. Use this guide to align material selection with your project budget and schedule.
High-Alumina
Panda / Gorilla / Dragontrail
Machining Difficulty
High hardness requires diamond tooling; edge chipping risk requires controlled feed rates.
Sapphire
Ultrasonic CNC Grinding
Machining Difficulty
Mohs 9 hardness -- the hardest material we machine. Requires ultrasonic-assisted CNC and specialized diamond wheels.
Expert-Level OnlyOptical Plastics
PMMA / PC / Composite
Machining Difficulty
Lower hardness enables faster cycle times; PC requires CNC routing (no laser) to prevent yellowing.
Custom Substrates
Borosilicate / Quartz
Machining Difficulty
Brittle fracture risk requires slow feed rates and frequent coolant flushing; quartz demands specialized tooling.
Difficulty Scale:
Verification Lab: Every Micron Counts
Our inspection protocol is the final gate. We use 2D/3D VMS and confocal microscopy to validate that every CNC path meets the drawing intent.
Dimensional Audit
Automated VMS measurement for 100% inspection of critical step dimensions and hole centers. Measurement uncertainty: ±0.001 mm.
Edge Quality Scan
50× micro-scan to ensure zero microscopic chipping that could compromise long-term structural reliability. Pass criterion: ≤ 0.03 mm edge breakout.
Surface Tension Test
Dyne testing post-CNC to ensure substrate surface energy is optimized for subsequent coating stacks. Target: ≥ 42 mN/m for AR/AF adhesion.
Ready for a Technical Feasibility Audit?
Submit your engineering drawings for a 24-hour DFM review by Iris's engineering team. We identify yield risks before they become production costs.
Prefer direct contact? Email Iris at [email protected]