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Custom Manufacturing Processes for Thermal Imaging Devices
With the advent of modern industry, custom imaging devices are becoming an indispensable tool in various industries.
12:25 17 April 2024
With the advent of modern industry, custom imaging devices are becoming an indispensable tool in various industries. From military usage to medical and industrial applications, the need for custom machining services is increasing day by day. However, the effectiveness of these devices depends upon their precision and manufacturing quality. In this article, we will explore the custom manufacturing processes that are involved in maintaining their performance and reliability.
Grip Texture Application via Laser Etching
To enhance the usability and ergonomics of custom imaging devices, grip textures are applied via a laser etching mechanism. The textured surface helps to reduce fatigue by distributing pressure evenly throughout the surface. The manufacturing phenomenon of laser etching is that it involves the use of high-powered lasers to remove material from the surface of the device, which ultimately creates a pattern that improves grip, comfort, and handling.
To do laser etching, The imaging devices are first cleaned, so that any dust particles if there are removed. After that, a specialized "GripTech Design Software" is used to create the desired patterns for etching. The design is fed into the laser etching machine control unit. Which is precisely programmed to etch the device's surface. The temperature requiresranges from (around 20-25°C or 68-77°F) for cleaning and preparing the surface. For etching, temperature depends upon the material used however, 100-200°C (212-392°F) is used in industries to ensure proper material removal and surface modification.
The Custom laser etching technique allows the engineers to have exceptional control over the depth and density of the texture. It will ultimately help in ensuring a consistent and uniform grip surface across all parts of the device. These features are quite evident specifically in rescue and military equipment. Where one has to hold thermal imagining devices for a long time. The texture grip ensures a firm hold, minimizing the risk of accidental drops.
Lens Production using precision Injection Molding
The manufacturing process of lens production begins with the preparation of chalcogenide glass. chalcogenide glass is made from elements such as sulfur, selenium, and tellurium. Due to its high refractive index, transparency in the infrared spectrum, and nonlinear optical behavior it is commonly used in fiber optics, inferred, and thermal imaging devices. This is crucial for effective custom imaging device performance, as it shows exceptional infrared transmission properties. The raw material for it is initially in the form of pallets and granules.
The injection molding technique used for the production of optical glass is the precision injection molding process. In precision injection molding, the pallets are carefully heated until their melting point is reached. The melted fluid is then pressured into the mold cavity, ensuring it fills every intricate detail of the mold. Temperature and pressure control are the most critical factors in the manufacturing of lenses. They prevent defects such as warping or uneven cooling and ensure uniformity in the finished product.
After that, the lenses are set to be solidified and cooled at a specific rate. The cooling process is very crucial and directly impacts the final quality of the lens. It will minimize internal stresses and help in achieving uniform shrinkage. One common method used for their cooling is through water channels integrated into the mold. Cold water is allowed to pass through these channels and molten material is allowed to cool. This technique is quite useful in achieving uniform cooling and reducing the risk of defects such as warping or sink marks.
Circuit Board Creation with Printed Circuit Board (PCB) Fabrication
Circuit layout design is the most paramount step in manufacturing PCBs, Altium Designer or Cadence Allegro PCB Designer is mostly used for circuit layout designs in the industry. After that, the fabrication process begins, firstly the substrate is prepared using the appropriate material like fiberglass-reinforced epoxy resin. These substrate materials are cut into desirable sizes as required.
In the next process, a thin layer of copper is deposited on the substrate surface, through chemical deposition methods. CVD is used due to its precise control of thickness and ability to produce uniform copper layers over large areas. This copper layer acts as a conductive pathway for the electric signals within the signals.
Once the CVD is done, the next step is to create the circuit pattern. This circuit pattern is created by selectively removing excess copper using a chemical etching process. In this process, a protective layer called resist is formed over the areas where copper traces are desired. The PCBs are then dipped in an etchant solution so that unwanted copper is removed.
Lens Mount Manufacturing using CNC Machining
Engineers with the help of computer-aided design software, probably CAD or Solid Works create a detailed blueprint of the lens mounts. The designs are prepared on accounting factors like heat dissipation properties, vibration resistance, electrical insulation properties, and tolerance for thermal expansion and contraction. Ansys software is quite helpful in analyzing these technical parameters through CFD analysis.
Once the designs are finalized, they are transferred to CNC machining equipment, which automates the manufacturing process with high precision and accuracy. CNC machining starts with selecting the appropriate material for the mounts, typically metals like aluminum or stainless steel known for their strength and durability. The selected material is then loaded onto the CNC machine, where a series of cutting and shaping tools, guided by the CAD designs, carve out the intricate shapes and features of the lens mounts. This process involves milling, drilling, and turning operations to create precise geometries that accommodate the lenses and allow for precise alignment within the thermal imaging device.
Throughout the machining process, operators closely monitor the parameters such as cutting speeds, feed rates, and tool paths to ensure the quality and accuracy of the finished mounts. Any deviations from the specifications are promptly addressed to maintain consistency and precision. After machining, the lens mounts may undergo additional finishing processes such as deburring, polishing, or surface treatments to enhance their appearance and functionality. These final touches ensure that the mounts meet the desired standards of quality and performance before they are assembled into thermal imaging devices.
Conclusion
Custom manufacturing processes contribute to the advancement of custom imaging devices. From PCB manufacturing to lens customization, modern manufacturing processes ensure the quality, reliability, and user satisfaction of thermal imaging devices. However, expert engineers’ machinists, and appropriate machine shops are the backbone of achieving precision in this industry.