Process
Diamond turning is a multi-stage process. Initial stages of machining are carried out using a series of CNC lathes of increasing accuracy. A diamond-tipped lathe tool is used in the final stages of the manufacturing process to achieve sub-nanometer level surface finishes and sub-micrometer form accuracies. The surface finish quality is measured as the peak-to-valley distance of the grooves left by the lathe. The form accuracy is measured as a mean deviation from the ideal target form. Quality of surface finish and form accuracy is monitored throughout the manufacturing process using such equipment as contact and laser profilometers, laser interferometers, optical and electron microscopes.
Temperature control is crucial, because the surface must be accurate on distance scales shorter than the wavelength of light. Temperature changes of a few degrees during machining can alter the form of the surface enough to have an effect. The main spindle may be cooled with a liquid coolant to prevent temperature deviations.
The diamonds that are used in the process are incredibly strong in the vertical downward direction but very weak in the upward and sideways directions.
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