Precision Polishing of

Metal Components
Presented by Dustin Lysiak
Polishing Lead at Optiforms, Inc.

Surface Finishers Educational Association

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About Dustin

• Polishing Lead at Optiforms, Inc.

• Essential manufacturer of electroformed metal components &
reflective surface finishes; based in Temecula, CA.

• Started by polishing jewelry

• 13 years experience lapping and polishing variety
of optical profiles
• Specializes in parabolic, ellipsoidal, and spherical
geometries

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Precision Polishing of Metal Components

The anatomy of a smooth polished surface to successful process execution:

• What is Polishing and Why We Do It

• How Precision Polishing is Different

• The Process of Precision Polishing

• Challenges & Pitfalls

• Tips for Precision Polishing

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What is Polishing?

• Process of progressively changing surface characteristics

• Leveling “Peaks & Valleys”
• Difficult, time consuming process
• Quality results depend on following rigid, disciplined set of steps

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Why Polishing Important?

Value added process used for:

• Lubricity
• Cleaning surfaces
• Preventing corrosion
• Cosmetic reasons

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What Goes Into A Precision Polish?

Creating sub-micron smooth finishes to properly reflect and focus light

with minimal degradation.

3 phases for success:

• Establish and maintain accurate profile geometry

• Establish accurate surface structure

• Apply final polish

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What Goes Into A Precision Polish?

5% Fingers Crossed

10% of Time =
Final Polish

85% of Time =
Grinding and Sanding
Macro & Micro
Corrections
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 Mandrel/Substrate
Polish
Machining

Precision
Polishing
CMM CMM
Measurement Measurement

Stage 1 Stage 3
Profile Correcting Final Polish
• Correct Undesirable Machining Features • Bring RMS in Spec.
• Smooth Profile • Apply Final Luster
Stage 2
Surface Smoothing
• Remove Heavy Abrasive Scratches
• Ready Surface for Final Polish
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First Stage – Profile Correction

Correction of large scale

unwanted machining features

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First Stage – Profile Correction

• RPM

• Polishing Tool Sweep Rate

• Pressure

• Cleanliness

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 End
Result

Finished First Stage of Polish

Newly Machined Part
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Key Controls for Detailing

• RPM

• Polishing Tool Sweep Rate

• Pressure

• Cleanliness

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Second Stage - Detailing

Goal is to remove all coarse abrasive grain scratches while further

refining the surface in preparation for final polish.

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Third Stage – Final Polish

Further refines the surface down

to the nanometer scale.

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Challenges & Pitfalls

Loss of profile/ geometry

What Can Go ●

● Poor surface structure

Wrong? ● Supplier Issues
● Contamination

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Verification
“If you can’t measure it, you can’t improve it.”
- Peter Drucker

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 Zeiss Contura - Touch probe CMM
Coordinate Measuring

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 FARO Arm - Articulating Arm CMM
Coordinate Measuring
KEYENCE - Vision CMM

Zeiss O-Inspect - Vision/Touch Probe CMM

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Scratch/Dig Comparison Standards

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SeeBrez - Vision & Touch Probe CMM

BATY - Optical Comparator

Vision & Optical Measuring Systems

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Vision & Optical Measuring Systems
Bowman - X-Ray Fluorescence ZYGO - ZeGage Interferometer

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Tips for Precision Polishing

• Heavier scratches may force you to go back steps

• Use Quality Ingredients

• Cleanliness is KEY!

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 Thank You!
Precision Polishing of Metal Components
Presented by Dustin Lysiak
Polishing Lead at Optiforms, Inc.
dlysiak@optiforms.com

www.optiforms.com | 1-951-296-1300 | sales@optiforms.com

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