Ultraprecise micro-machining of optical and mechatronic metal components with cleanroom assembly in Salem
Kugler GmbH Feinmechanik + Optik
SalemNew on Amplifa
About Kugler Precision
Kugler GmbH Feinmechanik + Optik in Salem on Lake Constance manufactures ultraprecise components, optical components and mechatronic systems for the semiconductor industry, medical technology, laser technology, metrology, optics & photonics as well as aerospace. The core competence is ultraprecise micro-machining: aspheric mirrors, freeform optics and mechanical precision parts are produced by diamond turning (including slow-tool non-circular turning), milling and grinding from aluminium, copper, non-ferrous metals and plastics, with form deviations in the range of 10 to 100 nanometers. In addition, the company offers 3D printing as a hybrid process in combination with machining and electroplating, material treatment and coating, precision assembly and cleanroom assembly (200 m², ISO 5 to ISO 4, pre-assembly ISO 7). Measuring equipment includes a Mitutoyo Legex coordinate measuring machine (MPEe 0.35 µm), 15 Fizeau interferometers, autocollimators and spectrometers. An in-house engineering team supports customers from optical design through to series production. The in-house contract manufacturing, which originated from the production of air-bearing ultraprecise guidances, rotary tables and machines, today forms the core business of the medium-sized company with around 100 employees, which supplies worldwide.
- Site
- Salem
- Processes
- Ultraprecise micro-machining (UP manufacturing), Ultraprecise milling, Ultraprecise turning, Ultraprecise grinding, Diamond machining (diamond turning, incl. slow-tool non-circular turning), Manufacture of ultraprecise optical components (aspheric mirrors, freeform optics), 3D printing (additive manufacturing, hybrid process with machining/electroplating), Material treatment & coating (among others electroplated layers)
- Materials
- Aluminium, Copper, Non-ferrous metals, Plastics, Ultraprecise micro-machining, Diamond machining, 3D printing / hybrid process, Cleanroom and precision assembly
- Certificates
- ISO 9001, ISO 9001 (TÜV Süd)
- Employees
- 100
- Industries
- Semiconductor industry, Medical technology, Laser technology, Metrology, Optics & Photonics, Aerospace
- 01
Raw material selection
- 02
Ultraprecise micro-machining (diamond turning, milling, grinding)
- 03
3D printing (hybrid process)
- 04
Material treatment & coating
- 05
Inspection (CMM, interferometry)
- 06
Cleanroom/precision assembly
- 07
Documented delivery
Materials & Processes
Aluminium
Main material for diamond-machined metal optical components such as aspheric mirrors and freeform optics.
Copper
Non-ferrous metal for mirror-finish diamond-machined optical and thermally stressed components.
Non-ferrous metals
Suitable for ultraprecise turning and milling with machining grooves in the nanometer range.
Plastics
Also diamond-turnable; also used in plastic 3D printing, e.g. for packaging.
Ultraprecise micro-machining
Milling, turning and grinding on in-house air- and oil-bearing machines for form accuracies better than the wavelength of light.
Diamond machining
Diamond turning incl. slow-tool non-circular turning produces mirror-finish surfaces from non-ferrous metals and plastics.
3D printing / hybrid process
Additively manufactured mirror bodies are coated via build plate or electroplating and subsequently diamond-machined.
Cleanroom and precision assembly
Assembly of complete assemblies such as mechatronic actuators and mirror units for lithography in the in-house cleanroom.
Locations
Salem
DEHeadquarters, manufacturing and cleanroom
- Materials
- Aluminium, copper, non-ferrous metals, plastics
- 3 hydrostatically mounted 5-axis micro machining centers (up to 500 mm axis travel)
- 8 diamond turning machines with slow-tool functionality
- 3 conventional 3/5-axis milling centers with automation
- In-house UP machining machines with air/oil bearings
- 3D printers
- Mitutoyo Legex coordinate measuring machine (700 × 700 × 600 mm, MPEe 0.35 µm)
- 15 Fizeau interferometers (measuring field up to 300 × 300 mm)
- 5 special interferometers
- 3 autocollimators
- 5 non-contact distance sensors
- Spectrometers
- Cleanroom 200 m², ISO 5 (partly ISO 4), pre-assembly ISO 7
- Ovens, UV chamber, balancing systems, temperature cabinets
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Ultraprecise micro-machining (UP manufacturing)Machining | Machining grooves in the nanometer range | – | – | – | Aluminium, Copper, Non-ferrous metals, Plastics |
| Ultraprecise millingMachining | – | – | – | – | – |
| Ultraprecise turningMachining | – | – | – | – | – |
| Ultraprecise grindingMachining | – | – | – | – | – |
| Diamond machining (diamond turning, incl. slow-tool non-circular turning)Machining | mirror-finish surfaces | – | – | – | Non-ferrous metals, Plastics |
| Manufacture of ultraprecise optical components (aspheric mirrors, freeform optics)Machining | Form deviations 10 nm to 100 nm | – | – | – | Aluminium, Copper |
| 3D printing (additive manufacturing, hybrid process with machining/electroplating)Additive | – | – | – | – | Metals, Plastic (packaging) |
| Material treatment & coating (among others electroplated layers)Surface | – | – | – | – | – |
| Cleanroom assembly (final assembly ISO 5, partly up to 4; pre-assembly ISO 7; 200 m²)Assembly | – | – | – | – | – |
| Precision assembly (assemblies, e.g. motor spindles, adaptive optics, satellite optics)Assembly | – | – | – | – | – |
| Mechatronic systems (motion/positioning of the highest precision)Assembly | – | – | – | – | – |
| CMM measurement (coordinate measurement, MPEe 0.35 µm)Inspection | MPEe 0.35 µm (350 nm) | 700 mm × 700 mm × 600 mm | – | – | – |
| Optical measurement (interferometry, form deviations 10–100 nm, measuring field up to 300 mm x 300Inspection | 10 nm to 100 nm | 300 mm × 300 mm | – | – | – |
| Engineering/Development (optics design, construction, UP machine technology, machining processes)Engineering | – | – | – | – | – |
12 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis micro machining center (hydrostatically mounted) | – | 3 | up to 500 mm axis travel | – | Salem |
| Diamond turning machine with slow-tool functionality (non-circular turning) | – | 8 | – | – | Salem |
| 3/5-axis milling center with automation (conventional, ultraprecise series parts) | – | 3 | – | – | Salem |
| Coordinate measuring machine | Mitutoyo Legex | 1 | 700 mm x 700 mm x 600 mm | – | Salem |
| Fizeau interferometer (flat and spherical measurements) | – | 15 | Measuring field up to 300 mm x 300 mm | – | Salem |
| Special interferometers (e.g. oblique incidence, roughness measurement) | – | 5 | – | – | Salem |
| Autocollimator (angle measurement) | – | 3 | – | – | Salem |
| Non-contact distance sensor | – | 5 | – | – | Salem |
| Spectrometer (reflection measurements) | – | – | – | – | Salem |
| 3D printer | – | – | – | – | Salem |
| Cleanroom (final assembly ISO 5, partly up to 4; pre-assembly ISO 7) | – | – | 200 m2 | – | Salem |
| Ultraprecision machining machines (in-house development, with air/oil bearings) | Kugler | – | – | – | Salem |
Additional services
Quality & Certification
Kugler is certified according to ISO 9001 (TÜV Süd) and works according to a lived "control plan". The measuring equipment includes a Mitutoyo Legex coordinate measuring machine (MPEe 0.35 µm) as well as 15 Fizeau interferometers, with which form deviations of 10 to 100 nm are captured.
| Evidence | Salem |
|---|---|
| ISO 9001 (TÜV Süd) |
History
Founded more than 40 years ago with the manufacture of air-bearing, ultraprecise guidances and rotary tables.
Development of in-house ultraprecise machines; the sale of machines and components as well as in-house contract manufacturing became established, with contract manufacturing today forming the core business.
For almost two decades, manufacturing and assembly of sophisticated components with high cleanliness requirements, e.g. for semiconductor lithography systems.