Mr. Bob Hallock Profile

Bob Hallock

Director of Engineering at Newport Corp a division of MKS Instruments

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Author

Publications (10)

Proceedings Article | 28 April 2009 Paper

Technologies for precision manufacture of current and future windows and domes

Bob Hallock, Aric Shorey

Proceedings Volume 7302, 73020V (2009) https://doi.org/10.1117/12.818864

KEYWORDS: Surface finishing, Polishing, Sapphire, Magnetorheological finishing, Wavefronts, Photovoltaics, Principal component analysis, Metrology, Interferometers, Manufacturing

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Proceedings Article | 25 September 2008 Paper

Applications and benefits of "perfectly bad" optical surfaces

Paul Dumas, Robert Hallock, Alex Pisarski

Proceedings Volume 7102, 71020G (2008) https://doi.org/10.1117/12.797718

KEYWORDS: Surface finishing, Magnetorheological finishing, Polishing, Wavefronts, Optics manufacturing, Rod lasers, Spherical lenses, Prisms, Neodymium lasers, Manufacturing

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Proceedings Article | 21 September 2007 Paper

Manufacturing meter-scale aspheric optics

W. Messner, C. Hall, P. Dumas, B. Hallock, M. Tricard, Stephen O'Donohue, S. Miller

Proceedings Volume 6671, 667106 (2007) https://doi.org/10.1117/12.734175

KEYWORDS: Polishing, Magnetorheological finishing, Surface finishing, Optics manufacturing, Aspheric lenses, Aspheric optics, Optical testing, Mirrors, Metrology, Astronomical imaging

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Proceedings Article | 14 September 2007 Paper

Complete sub-aperture pre-polishing and finishing solution to improve speed and determinism in asphere manufacture

Paul Dumas, Christopher Hall, Bob Hallock, Marc Tricard

Proceedings Volume 6671, 667111 (2007) https://doi.org/10.1117/12.734684

KEYWORDS: Magnetorheological finishing, Polishing, Aspheric lenses, Surface finishing, Manufacturing, Photovoltaics, Metrology, Optical spheres, Head, Optics manufacturing

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Proceedings Article | 14 May 2007 Paper

Magnetorheological Finishing of freeform optics

Christopher Hall, Andrew Jones, Bill Messner, Bob Hallock

Proceedings Volume 10316, 103160J (2007) https://doi.org/10.1117/12.719886

KEYWORDS: Polishing, Optical spheres, Raster graphics, Surface finishing, Magnetorheological finishing, Freeform optics, Photovoltaics, Aspheric lenses, Spindles, Optical design

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Proceedings Article | 2 May 2007 Paper

Improving surface figure and microroughness of IR materials and diamond turned surfaces with magnetorheological finishing (MRF)

Christopher Supranowitz, Christopher Hall, Paul Dumas, Bob Hallock

Proceedings Volume 6545, 65450S (2007) https://doi.org/10.1117/12.719792

KEYWORDS: Magnetorheological finishing, Surface finishing, Polishing, Single point diamond turning, Infrared materials, Diamond, Diamond turning, Wavefronts, Optics manufacturing, Silicon

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Proceedings Article | 2 May 2007 Paper

Improvements in large window and optics production

Bob Hallock, Bill Messner, Chris Hall, Chris Supranowitz

Proceedings Volume 6545, 654519 (2007) https://doi.org/10.1117/12.719864

KEYWORDS: Magnetorheological finishing, Polishing, Surface finishing, Aspheric lenses, Sapphire, Metrology, Wavefronts, Optical spheres, Aspheric optics, Optics manufacturing

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Fabrication of large optics has been a topic of discussion for decades. As early as the late 1980s, computer-controlled equipment has been used to semi-deterministically correct the figure error of large optics over a number of process iterations. Magnetorheological Finishing, MRF®, was developed and commercialized in the late 1990's to predictably and reliably allow the user to achieve deterministic results on a variety of optical glasses, ceramics and other common optical materials. Large and small optics such as primary mirrors, conformal optics and off-axis components are efficiently fabricated using this approach. More recently, specific processes, MR Fluids and equipment have been developed and implemented to enhance results when finishing large aperture sapphire windows. MRF, by virtue of its unique removal process, overcomes many of the drawbacks of a conventional polishing process. For example, lightweighted optics often exhibit a quilted pattern coincident with their pocket cell structure following conventional pad-based polishing. MRF does not induce mid-frequency errors and is capable of removing existing quilt patterns. Further, odd aperture shapes and part geometries which can represent significant challenges to conventional polish processing are simply and easily corrected with MRF tools. Similarly, aspheric optics which can often present multiple obstacles-particularly when lightweighted and off-axis−typically have a departure from best-fit sphere that is not well matched with to static pad-based polishing tools resulting in pad misfit and associated variations in removal. The conformal subaperture polishing tool inherent to the QED process works as well on typical circular apertures as it does on irregular shapes such as rectangles, petals and trapezoids for example and matches the surface perfectly at all points. Flats, spheres, aspheres and off-axis sections are easily corrected. The schedule uncertainties driven by edge roll and edge control are virtually eliminated with the MRF process. This paper presents some recent results of the deterministic finishing typified by the QED product line and more specifically of its large-aperture machines, presently capable of finishing optics up to one meter in size. Examples of large sapphire windows and meter-class aspheric glass optics will be reviewed. Associated metrology concerns will also be discussed.

Proceedings Article | 6 July 2006 Paper

Cost-effective subaperture approaches to finishing and testing astronomical optics

Marc Tricard, Aric Shorey, Bob Hallock, Paul Murphy

Proceedings Volume 6273, 62730L (2006) https://doi.org/10.1117/12.672385

KEYWORDS: Magnetorheological finishing, Polishing, Surface finishing, Mirrors, Optics manufacturing, Interferometers, Aspheric lenses, Metrology, Optical spheres, Photovoltaics

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The fabrication and metrology of astronomical optics are very demanding tasks. In particular, the large sizes needed for astronomical optics and mirrors present significant manufacturing challenges. One of the long-lead aspects (and primary cost drivers) of this process has traditionally been the final polishing and metrology steps. Furthermore, traditional polishing becomes increasingly difficult if the optics are aspheric and/or lightweight. QED Technologies (QED(r)) has developed two novel technologies that have had a significant impact on the production of precision optics. Magnetorheological Finishing (MRF(r)) is a deterministic, production proven, sub-aperture polishing process that can enable significant reductions in cost and lead-time in the production of large optics. MRF routinely achieves surface figure accuracy of better than 30 nm peak-to-valley (better than 5 nm rms) and microroughness better than 1 nm rms on a variety of glasses, glass ceramics and ceramic materials. Unique characteristics of MRF such as a comparatively high, stable removal rate, the conformal nature of the sub-aperture tool and a shear-mode material removal mechanism give it advantages in finishing large and lightweight optics. QED has, for instance, developed the Q22-950F MRF platform which is capable of finishing meter-class optics and the fundamental technology is scalable to even larger apertures. Using MRF for large optics is ideally partnered by a flexible metrology system that provides full aperture metrology of the surface to be finished. A method that provides significant advantages for mirror manufacturing is to characterize the full surface by stitching an array of sub-aperture measurements. Such a technique inherently enables the testing of larger apertures with higher resolution and typically higher accuracy. Furthermore, stitching lends itself to a greater range of optical surfaces that can be measured in a single setup. QED's Subaperture Stitching Interferometer (SSI(r)) complements MRF by extending the effective aperture, accuracy, resolution, and dynamic range of a standard phase-shifting interferometer. This paper will describe these novel approaches to large optics finishing, and present a variety of examples.

Proceedings Article | 19 August 2005 Paper

Cycle time and cost reduction in large-size optics production

Bob Hallock, Aric Shorey, Tom Courtney

Proceedings Volume 5869, 58690D (2005) https://doi.org/10.1117/12.617779

KEYWORDS: Polishing, Magnetorheological finishing, Surface finishing, Optics manufacturing, Mirrors, Abrasives, Glasses, Aspheric lenses, Optical fabrication, Lightweight mirrors

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Proceedings Article | 18 May 2005 Paper

Recent advances in deterministic low-cost finishing of sapphire windows

Bob Hallock, Paul Dumas, Aric Shorey, Marc Tricard

Proceedings Volume 5786, (2005) https://doi.org/10.1117/12.603930

KEYWORDS: Magnetorheological finishing, Polishing, Surface finishing, Sapphire, Wavefronts, Abrasives, Particles, Interferometers, Surface roughness, Magnetism

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Showing 5 of 10 publications

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