Ultra-precision manufacturing is a deterministic method of producing optical-grade components. Continuous and interrupted machining operations are the main focus of this research with the goal of improving the manufacturing community’s knowledge. The original contributions of this research are: (a) a comprehensive analysis of the cutting mechanics of single-crystal germanium, specifically studying the effects of major crystal orientation and cutting speed; (b) methodology for producing flat, damage-free test samples in single-crystal germanium; and (c) machine learning models for estimating surface finish parameters Sa, Sq, and Sz in SPDT of single-crystal germanium and oxygen-free high-conductivity copper. As a final product of this research, a pair of collimating lenses were produced for an external collaborator.
