07 Research and teaching, trade literature, trade associations and organisations
07.05 Reseach institutes and projects
Reseach institutes and projects
Product category: Vacuum coating equipment
The Bühler Leybold Optics AluMet 1800V is a highly economic, high-throughput, batch-type thermal evaporation machine for thin-film vacuum-coating of three-dimensional parts. Its double-door “clam-shell” configuration allows highly productive processing with each door holding six planetary pylons to carry the substrates. Each single pylon has a load capacity of up to 35 kg, is effectively 1500 mm long and has a usable diameter of 540 mm. The double-door design enables extremely efficient operation, as each door can be easily loaded and unloaded independently while the other is still processing.
High productivity from a generous load capacity and short cycle times
The intuitive state-of-the-art human-machine interface (HMI) of the AluMet 1800V and its fully automated process control consistently guarantee high throughput with perfect results. Highly efficient processing is further aided by the double-door design with a set of six pylons per door. Offering a coating area of up to 15 m² per batch the AluMet 1800V delivers tremendous productivity. The powerful vacuum pumping system, the highly efficient thermal evaporators and high-rate plasma-enhanced chemical vapor deposition (PECVD) sources are the key to short cycle times. For example, the AluMet 1800V can deposit a highly reflective aluminum layer, plus protective top coat, onto a typical car-lamp reflector in approximately 20 min-.
Low production cost thanks to efficient consumable utilization The AluMet 1800V highly efficiently uses production-cost-driving consumables such as evaporator filaments and aluminum evaporation material. Since the lifetime of the filaments is physically limited to a certain number of evaporation cycles, the AluMet 1800V’s high load capacity helps to drastically lower the consumables cost per coated piece. Furthermore, the optimized aluminum evaporator geometries allow for a maximum collection efficiency, which results in a high evaporation material utilization.
Robust design for high reliability Employed in the automotive industry worldwide, the AluMet 1800V is more than able to demonstrate its unique reliability and robustness in a mass production context. This unbeaten reliability is the result of ongoing robust and smart machine design. All key components such as the evaporators and the PECVD stations are designed for 24/7 production and to ensure a high machine uptime, all serviceable components are easy to access and simple to maintain.
Versatile pylon system for more production flexibility The planetary substrate holder system with its six pylons per door is capable of handling a wide range of substrate types and sizes. This makes Bühler Leybold Optics’ AluMet 1800V a very versatile and flexible system, suitable for many different production scenarios and environments. In addition, the ergonomic design of the pylon holder system allows fast and easy handling of the pylons during loading and unloading of substrates.
Compact design means minimum floor space requirements The AluMet 1800V is mounted in a compact and easy-to-handle steel frame. As a result, the system has a space-saving footprint of approx. 45 m² in total. The machine’s steel frame makes its installation and if required, relocation, fast and straightforward.
The Bühler Leybold Optics ARES machine platform has been conceived to meet the specific requirements of East Asian mass manufacturers for the cost-optimized mass production of components for the precision optics industry. Derived from our SYRUSpro series, the configuration is thoroughly streamlined according to the specific application, but never compromises on quality. Its ease of use in combination with production proven local components makes the ARES series a powerful tool for cost-effective 24/7 high volume production based on one hundred percent Bühler Leybold Optics technology. High reliability through proven design in combination with a fast return on investment.
A fast return on investment is achieved by ARES coaters since they provide a coating technology which perfectly matches market demands for a very reasonable capital outlay. The machine concepts themselves are based on the proven designs of our SYRUSpro series. In such ARES coaters are equipped with key components designed and made by Bühler Leybold Optics and use in parallel numerous locally sourced parts, adapted to specific customer requirements.
Various chamber sizes to meet the customers' demands.
ARES series machines are available in various chamber sizes, from ARES 700, ARES 1100 and ARES 1350 to the high volume production systems ARES 1500 and ARES 2000. A high variety of coating operations can be implemented into the production process in a cost-efficient manner. At the same time, ARES coaters deliver a very strong performance relative to requested coating specifications.
The Bühler Leybold Optics CompactMet is an economic, compact and ultra-fast batch-type aluminum evaporation machine for vacuum coating of three-dimensional parts such as automotive plastic head light and tail light reflectors. The machine’s patent pending concept delivers clear advantages for flexible large-scale production. The substrates are loaded onto two easily accessible rotating pylons on each of the machine’s two doors, each pylon having a usable length of 1500 mm and a diameter of 540 mm. This double-door design minimizes delays between batches, as one door’s pylons can be loaded and unloaded while the others are being processed, a feature which helps to maximize productivity.
High reliability thanks to smart und robust design The CompactMet is deployed in daily mass production in the automotive industry and has demonstrated unmatched reliability and productivity. Key components such as the vacuum pump set, evaporation system and the plasma-enhanced chemical vapor deposition (PECVD) station are designed for a 24/7 machine operation. Maintenance requirements have been kept to a minimum by the consistent implementation of a robust and smart machine design. Furthermore, all serviceable parts are easily accessed and simple to maintain, thus ensuring a high machine uptime.
Efficient processing for high productivity and flexibility Besides the intuitive and state-of-the-art human-machine interface (HMI), the machine concept itself offers considerable benefits for industrial mass production applications. The double-door “clam shell” configuration with two substrate holders per door facilitates highly efficient processing. The balance between output per batch and cycle times allows maximum productivity while offering a high degree of flexibility. For example, in combination with the enhanced vacuum pumping system, this design enables cycle times of less than 7 min for the deposition of a highly reflective aluminum layer, plus protective top coat, onto a typical car-lamp reflector.
Consistent and perfect end product quality through reliable and innovative technology Well-proven key components such as the high-rate thermal aluminum evaporator unit and the high-performance PECVD station, with its four MF-powered electrodes, ensure an excellent and consistent quality of the deposited aluminum and siloxane protective top-coat layers. Also, newly developed and innovative components like the high-performance cryo-coil, which offers a tremendous high-vacuum pumping capacity and ensures an optimum water-vapor partial pressure during processing, guarantee a solid system performance, which in turn maintains very high quality levels.
Compact design for space-saving deployment and fast repositioning With an optimized footprint (approx. 30 m² in total) the CompactMet is mounted in a compact and easy-to-handle steel frame. This allows easy and fast installation of the system and also relocation, if necessary. Thus once installed, the CompactMet system occupies a minimum of floor space.
(80 … 720 pairs/8 h) Bühler Leybold Optics’ CHC series provides a comprehensive cleaning and hard coating solution for all ophthalmic needs within one single machine. Based on a thorough preparation of the substrates utilizing ultrasonic pre-cleaning, the CHC machines provide outstanding coating quality on lenses hand in hand with Bühler Leybold Optics process know-how. Premium scratch resistance of the lens surfaces is guaranteed by dip-coating processes using hard-coating lacquer material. The CHC series is available to suit very small production operations right up to large-scale, high-volume production.
Cutting-edge technology for best process results
The auto-tuning ultrasonic generators and de-ionized water rinsing system provide the highest cleaning quality for lenses. Outstanding cleanliness is achieved by oscillating the lenses during both the cleaning and the rinsing process. With the precise and perfect coating of lacquer via dip-coating, combined with a pre-curing capability, the CHC series contributes significantly to the highest quality requirements of finished products.
Fully automated design, ease of use and control Together with reliable high-quality processes, a further focus is the CHC series’ ease of use. Optimum process conditions are achieved using automated coating speed profiling and additional auto-tuning functions.
The human-machine interface is realized via color touch screen for easy process initiation, control and termination.
Different sizes available for application flexibility
The CHC series consists of three different sizes, from low-volume (LEYBOLD OPTICS CHC 20) via mid-volume (LEYBOLD OPTICS CHC 60) machines to versions which match high-volume production requirements. Thus, the CHC series is well-suited to fulfill a variety of different applications. Different electro-polished 316 stainless steel tanks for various lens coating materials are standard, as well as built-in Class 100 HEPA laminar-flow filtration.
Product category: Sputtering targets for flat glass coating
The DynaJet is the newest member of the Dyna family of metallizing systems. This batch sputtering system combines the best of all PVD expertise that Bühler has to offer. The proven IPT cathode provides a new dimension in productivity. High target utilization offers lower cost of ownership due to a long target lifetime. The turbo molecular pump system needs only a fraction of the electrical energy and cooling water compared to conventional systems. All this allows for a significant reduction of the yearly cost of ownership.
Energy efficient metalizer for lower OPEX Average energy consumption is an important aspect for the cost of ownership. The new pumping system of the DynaJet with TMP saves 800.000 kWh in 10 years compared to competing machines in the market. Together with faster ramp-up and ramp-down times for the high vacuum pumps and lower water consumption, DynaJet is setting a new benchmark, making it the best investment for the future.
Higher throughput and lower manpower costs The automatic substrate load- and unload function allows a production line that can work automatically with higher throughput and lower manpower costs. A dry air venting system allows for constant production independent environmental conditions. This feature permits faster pump down and a higher metallization quality resulting in a shorter cycle time.
Small footprint for optimized production space With a required floor space of less than 10m², DynaJet is easy to integrate into your existing factory. The machine is on a compact, container-sized frame for easy transport on site or to another production facility.
PECVD and PVD at the highest rate and best homogeneous distribution The worldwide proven IPT cathode and an optimized cryo-coil guarantee the best PVD homogeneity. A semi-transparent sputter layer is another possible application. The optimized Bühler Arc management ensures a stable sputtering process. New developments in the plasma-enhanced chemical vapor deposition (PECVD) process enable high speed top coating.
As a globally active high-tech company, specialized in the development and manufacturing of vacuum deposition equipment, LEYBOLD OPTICS’ expertise covers a variety of fields and applications. These range from coatings for architectural glass, display and other large area surfaces, over precision optics, eyeglass coatings and optical filters to industrial coatings such as automotive, packaging and (flexible) electronics.
Heritage and history
The roots of LEYBOLD OPTICS go back to the foundation of two companies by legendary pioneers Ernst Leybold and Wilhelm Carl Heraeus in the middle of the 19th century – 164 years ago. What follows is the story of the rise of two firms to become the dominating companies in vacuum technology worldwide throughout the 20th century – a story of groundbreaking inventions and entrepreneurial spirit. In 1967, Leybold and Heraeus merged into one company – in a way the incubator of LEYBOLD OPTICS.
Since the beginning of 2012 LEYBOLD OPTICS belongs to Bühler Group, located in Switzerland. Bühler is a specialist and technology partner for plant, equipment, and services for processing basic foods and for manufacturing advanced materials. With its expertise and over 150 years of experience, Bühler time and again rolls out unique and innovative solutions for its customers, helping them achieve success in the marketplace. Over the decades, Bühler has come to be acknowledged as a reliable partner, thanks to its distinct commitment to quality and its global presence. Bühler Group operates in over 140 countries and has a global payroll of over 10,000 employees.
As a globally active high-tech company, LEYBOLD OPTICS is headquartered in Alzenau (Germany) with additional production facilities in Cary (USA) and Beijing (China). A network of sales and service centers all around the globe ensures close contact to the customer base and effective support for more than 2,500 systems in the field. The global presence of the family-owned Bühler Group in more than 140 countries further strengthens Leybold Optics’ position worldwide as a reliable supplier for thin film coating equipment. The bundling of the competencies of Bühler and Leybold Optics creates a large pool of expertise and experience that can be utilized for developing innovative customer solutions. A top priority for LEYBOLD OPTICS is innovation leadership in key areas such as coating technologies, machine automation and software, as well as world-class customer service.