Optical Mirrors Design Characteristics

,Step	Feature	Specification	Characteristics / Benefits	Limitations
1	Specify the Quantity	Quantity Required	• The larger the quantity of pieces that can be used in an application, the less expensive each part becomes as material, labor and coating charges can be divided over the total number of parts. • Advanced Optics has the ability to modify catalog/overrun optical mirrors (when possible) to reduce costs and lead times.	Small number of prototypes may be more expensive due to lot charges for glass and coating.
2	Select the Material	Soda-lime Glass	• Commonly known as float glass. • Least expensive of all glass types. • Can be polished 1-3 waves/inch. • May be tempered making it 3 times stronger than non-tempered glass.	• Softer than borosilicate glass making it easily scribed and broken. • Cannot be precision polished and is available in commercial grade only (1-3 waves/inch). • Has the lowest thermal shock and chemical resistance of all glass materials used to fabricate optics. • Not as scratch resistant as borofloat, quartz or fused silica.
		BOROFLOAT®33	• Borofloat®33 is a borosilicate glass with a low thermal expansion. • Good all around general purpose mirror substrate that is moderately priced. • Easier to polish than harder materials such as fused quartz, fused silica or Zerodur® and is much less costly.	• May be polished down to λ/10, but is not suitable for polishing down to λ/20. • 2-3 times more costly than float glass (soda-lime glass). • Not as thermally shock resistant as fused quartz or fused silica. • Cannot be fully tempered like soda-lime glass. • Not suitable for extreme high temperature conditions and will not hold its shape over 450° C for long periods of time.
		N-BK7®	• Common borosilicate crown glass know for its low bubble and inclusion content. • Economically priced, may be used as an optical mirror substrate, but more commonly used in the manufacture of optical windows.	N-BK7 is not recommended for applications where thermal shock is a factor.
		Viosil	• Viosil is a synthetic quartz glass substrate manufactured by ShinEtsu. • The absence of bubbles and inclusions make it an excellent window substrate. • It offers excellent chemical resistance, mechanical strength and high heat resistance.	Carry glass only up to .250” thick.
		Fused Silica	• Made from a synthetically derived silicon dioxide that is extremely pure. • It is a colorless, non-crystalline silica glass. • The main difference between fused silica and fused quartz is that the former is composed of a non-crystalline silica glass while the latter is composed of a crystalline silica glass. • Advantages of fused silica over fused quartz include; greater ultraviolet and infrared transmission, a wider thermal operating range, increased hardness and resistance to scratching and a lower CTE which provides resistance to thermal shock over a broad range of temperatures. • As opposed to other less costly glasses, the surface figure (flatness) of optical mirrors made of fused silica are not at risk in applications that expose the material to coatings applied at high temperatures or applications that require the material to remain flat at high and/or varying temperatures. • Fused silica is also chemically resistant and provides superior transmittance in the UV spectrum when compared to fused quartz. • Fused silica comes in many grades with the most common being 7980 2G. Please visit Corning’s Quality Grade Selection Chart for further information.	• Very hard glass making it more difficult to fabricate than float or crown glasses. • Raw material is more costly than float or crown glasses. • The homogeneity of fused silica exceeds that of crystalline fused quartz, however standard 7980 2G (UV grade) material has a higher OH content which cause dips in transmission at 1.4µm, 2.2µm and 2.7µm. These dips can be eliminated by using a more expensive grade of IR fused silica.
		Quartz	• Made from naturally occurring crystalline quartz or silica grains whereas fused silica is entirely synthetic. • Fused quartz and fused silica are both extremely pure materials and have very low thermal expansion rates. However, fused quartz is more cost effective. • Known for its incredible thermal shock resistance, chemical resistance and for being an excellent electrical insulator. • Fused quartz has more metallic impurities and a lower OH content than standard UV grade fused silica which has dips in transmission at 1.4µm, 2.2µm and 2.7µm. These dips can be eliminated by using a more expensive grade of IR fused silica.	• Very hard glass making it more difficult to fabricate than float or crown glasses. • Raw material is more costly than float or crown glasses, but less expensive than fused silica. • Fused quartz shares many of the same advantages of fused silica with the exception of metallic impurities found in the mined, natural quartz or silica sand. These impurities inhibit the materials ability to transmit well in the UV spectrum.
		ULE® Low Expansion Glass	ULE® 7972 is a titania-silicate glass with near zero expansion characteristics that have made it the material of choice in unique applications such as machine tool reference blocks, gratings, interferometer reference mirrors, and telescope mirrors.	Low expansion glasses offer unique characteristics that make them the material of choice for certain applications, although the material tends to be more costly than its float or crown glass counterparts.
		ClearCeram®-Z	ClearCeram®-Z is a glass-ceramic material that offers an ultra low thermal expansion and is Ohara's equivalent to Zerodur® which is manufactured by Schott.	Low expansion glasses offer unique characteristics that make them the material of choice for certain applications, although the material tends to be more costly than its float or crown glass counterparts.
		ZERODUR®	• Glass-ceramic material which has a yellowish tint. • Extremely low thermal expansion coefficient which approaches zero allowing it to be used to produce mirrors that retain their surface figures in extremely cold environments such as space. • The CTE of Zerodur® is lower than ULE, fused quartz and fused silica. • Known for its low level of bubbles and striae, internal stress and its excellent chemical resistance.	• Yellow tint. • Low expansion glasses offer unique characteristics that make them the material of choice for certain applications, although the material tends to be more costly than its float or crown glass counterparts.
3	Determine the Size/Shape	Round Rectangular Square Custom	Round provides the best opportunity for obtaining flatness/accuracy.	Square, rectangular and custom shapes provide more challenges to maintaining surface flatness.
4	Refine your Mechanical Tolerances	Defines the acceptable limits of both size and thickness required for an application.	Specified in inches or mm and typically given a +/- value. • Round: Provide tolerance for diameter. • Rectangular/Square: Provide tolerance for LxW. • Thickness: Provide tolerance for thickness.	• Tighter tolerances for diameter and LxW are typically easier to hold than for thickness. • Extremely tight tolerances available, but may require specialized techniques and can reduce yield leading to increased costs. • Loosening your tolerances can reduce costs.
5	Establish the Correct Accuracy	Commercial grade 1-3 waves/inch Precision polished λ/4 or λ/10 Precision polished λ/10 or λ/20	Commercial grade mirrors are generally made from less expensive materials such as soda-lime glass and borofloat. Working grade mirrors are polished either λ/4 or λ/10 and most often made of Borofloat®33 or N-BK7. • Precision grade mirrors are polished either λ/10 or λ/20 and are typically made from harder glass materials such as quartz, fused silica or Zerodur®. • To achieve the best accuracy, optical mirrors are polished in a 6:1 aspect ratio (diameter to thickness). The higher the ratio, the greater probability the glass will distort during the manufacturing process. When the glass is deblocked after polishing, mirrors with non-standard aspect ratios may spring as they do not have the stability to hold surface flatness. • Advanced Optics manufactures precision grade mirrors with non-standard aspect ratios.	Achievable surface accuracy is dependent on choice of substrate and thickness of material.
6	Specify the Surface Quality	Provide the required Scratch and Dig	80-50: Commercial grade mirrors, suitable for non-critical applications, easily manufactured, lowest cost. 60-40 or 40-20: Working grade mirrors, precision quality, suitable for most scientific and research applications as well as low to medium power lasers, intermediate price point. 20-10 or 10-5: Precision grade, suitable for high power lasers, highest cost.	Extremely tight tolerances available, but may require specialized techniques and can reduce yield leading to increased costs.
7	Provide Parallelism (if required)	Amount of wedge or variation in thickness allowed over the surface of a part.	It is defined in arc minutes (an angular measurement that is 1/16th of a degree) or arc seconds where 60 arc seconds is equal to 1 arc minute. Advanced Optics can hold parallelism of < 2 arc seconds.	Extremely tight requirements for parallelism require specialized manufacturing techniques which may reduce yield and increase manufacturing costs.
8	Define the Clear Aperture/ Edge Bevel Requirements	The clear aperture is the percentage of useable area of an optical mirror. An edge bevel or safety chamfer is applied around the edge of an optical mirror.	Normally 90% or advise requirement. An edge bevel or safety chamfer is applied around the edge of an optical mirror to eliminate sharp edges and reduce edge chips caused by cutting of the glass. Typically between .010"-.040" face width at 45 degrees depending on size of part, please advise preference and tolerance.	Very small edge bevels with tight tolerances will add additional costs.
9	Choose the Proper Coating	Metallic and Dielectric coatings available for the UV-VIS-NIR regions.	• Provide the wavelength(s) of interest and % reflectivity required. • Provide the intended AOI (angle of incidence) for the optical mirror.	Custom coatings for a small quantity of parts may add additional expense.
10	Customization	The following attributes can be added to customize your mirror.	• Shapes: Provide drawing of custom shape. • Holes and Notches: Provide location, size with tolerances. • Custom Bevels: Provide location, depth and angle. • Custom Coatings: Provide expected % of reflectivity over wavelength(s) of interest and AOI (angle of incidence).	Additional features may add lead time and cost.

10 Steps to Consider when Designing Your Optical Mirror

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