Why do aspherical lens elements cost more to make?

Asked 5/30/2012

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Aspherical lens elements often make a lens noticeably more expensive. Since they are still made from glass blanks that are ground and polished, why does changing the surface from spherical to aspherical add so much cost? What is different about the manufacturing process?

Originally by Photography Stack Exchange contributor. Source · Licensed CC BY-SA 4.0

Photography Stack Exchange contributor

14y ago

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A lot of it is manufacturing costs, but it's not really quite like @Matt has described it (or at least not how I understand his description).

With spherical elements, you normally take a number of blanks, and mount them all to a roughly sphere-shaped holder (with "divots", so to speak, where you're going to mount the blanks). Then you have a sphere-shaped grinder/polisher that mounts around the outside (for a convex surface) or inside (for a concave surface) and lets you grind/polish a large number of elements at a time. Th exact number depends on the diameter and curvature of the element, but we're typically talking at least a few dozen, and especially for smaller elements, can be hundreds.

There are several ways of making aspherical elements (ground, molded, hybrid), but they have one thing in common: every one of them requires that you process elements individually instead of in large groups. Until fairly recently (1980's or so) about the only way to do aspherical elements was to grind them individually by hand. Those were/are restricted to very limited production at extremely high prices (Leicas, Nocturnal Nikkors, etc.) There are ways to semi-mass produce them now, but that's still a matter of loading one blank into a machine, and automating most of processing that one blank, then taking it out and loading one more blank. In most cases, that's in addition to doing normal spherical grinding as well.

Originally by user603. Source · Licensed CC BY-SA 4.0

user603

14y ago

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Aspherical elements are mainly more expensive because they are harder to manufacture precisely at scale.

A spherical surface is relatively simple to make: the lens blank can be rotated against a matching polishing tool, and the geometry naturally produces a sphere. Manufacturers can also process many spherical elements together using tooling matched to that curvature, which lowers cost.

An aspherical surface is different because it is not a simple constant-curvature shape. It requires a very specific profile across the whole surface, so you can’t rely on simple rotational polishing in the same way. Instead, production typically needs more specialized methods such as precision grinding, computer-controlled polishing, molding, or hybrid techniques.

Those processes demand tighter control, more complex tooling, and often more individual attention per element. In short: spherical lenses benefit from simpler, highly repeatable mass-production methods, while aspherical lenses require more advanced and precise manufacturing, which raises cost.

UniqueBot

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14y ago

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