How lenses are made...in Leicester!


How lenses are made...in Leicester!
A tour of the factory is a wonderful insight into the production of these instruments.
We start with the raw material. With over 100 types of glass to choose from Cooke select a pre moulding depending on the lens model.
Grinding
We move into the main building now and are greeted by the industrial sound of machines at work. The first stop for our glass is the CNC (Computer Numerically Controlled) machines. These are high precision machines which grind the glass establishing the optical requirements for the lens.
Polishing
From here it’s a short journey next door to the polishing area. The glass elements are held on the base of the polisher and are slowly polished by a rotating robotic arm. One element at a time is held although due to the design of the polishing mount several elements can be held at once if needed.
There is a rack full of polishing moulds for the many different shapes of Cooke lenses, the skilled craftsmen select the shape depending on the curvature required.
Aspherical lens, with their different geometry, take a different route through this area.
At all times throughout the factory you are faced with state of the art technology working in perfect synergy with Victorian aged machines from the early 20th century.
Coating
Coatings are applied before the final grinding takes place, at all times throughout the process the elements are constantly measured, monitored and cleaned.
Edging
The edges of the elements are sprayed with black epoxy paint, if they were left clear then light would create reflections and ghosting between the elements.
Assembly
With the element completed it’s now time to assemble the lens. The metal work and on average the 12 elements required for an S4 lens are assembled in the “fitting” room. It’s a quiet calm atmosphere in here, no industrial noise with a very “hand built” feel to it all.
Once assembled it is taken apart, totally stripped down, for cleaning and washing before being carefully reassembled in a dust free room.
The focus is checked for each increment with the scales then engraved specifically for that lens. Cooke /i lenses (we’ll come on to those later) are computer soak tested to continuously monitor readouts of metadata that will be used in post production.
After around 3 month (given normal assembly schedules) from leaving the raw moulding store the finished hand crafted lens is ready for packaging, shipping and production!

Tags: cooke | iss027 | leicester | glass | cnc | coatings | assembly | factory | N/A
Contributing Author N/A

Read this article in the tv-bay digital magazine
Article Copyright tv-bay limited. All trademarks recognised.
Reproduction of the content strictly prohibited without written consent.

Related Interviews
  • Cooke Optics technology at IBC 2014

    Cooke Optics technology at IBC 2014

  • Cooke Optics talk anamorphic at IBC 2014

    Cooke Optics talk anamorphic at IBC 2014

  • Cooke Optics on BroadcastShow LIVE at IBC 2013

    Cooke Optics on BroadcastShow LIVE at IBC 2013

  • Cooke Optics at BVE 2012

    Cooke Optics at BVE 2012

  • Cooke at IBC2011

    Cooke at IBC2011

  • New Filters from Schneider Optics at NAB 2018

    New Filters from Schneider Optics at NAB 2018

  • Pixel Power at NAB 2014

    Pixel Power at NAB 2014

  • Pixel Power on BroadcastShow LIVE at IBC 2013

    Pixel Power on BroadcastShow LIVE at IBC 2013

  • Pixel Power at NAB 2013

    Pixel Power at NAB 2013


Related Shows
  • Bubble and Squeak: Live and Loud from Monday at IBC 2013

    Bubble and Squeak: Live and Loud from Monday at IBC 2013


Articles
Making the Workflow Flow
Bruce Devlin - new The toughest things about being the Standards Vice President (SVP) is that everyone expects standards to be the most important thing. In all the systems that I’ve designed and deployed over the years, I've yet to find any production workflow that is 100% standards based. True, the core technologies may well be standards based, but the overall workflow is made up of many technology pieces from open source code, through de-facto delivery specifications based upon SMPTE or Trade Association Specifications that in turn depend on full, International Standards to work. I can already hear some folks saying "In the good old days, everything used standards", but I beg to disagree.
Tags: iss138 | pye museum | pye-philips | smpte | ietf | ieee | w3c | aes | Bruce Devlin - new
Contributing Author Bruce Devlin - new Click to read or download PDF
How the Womens World Cup was Boosted by Broadcast
John Griffiths As we write this article, England’s Lionesses have just beaten Norway 3-0 and are smashing viewing figure records, with 6.9 million viewers tuning in to watch them play Cameroon on BBC One. Rewind to the previous World Cup in 2015, and England’s group and early stage knockout games tempted up to 2.5 million viewers for each match. It’s safe to say that women’s football is finally having its moment; what was perhaps once considered a niche sport is finally gaining momentum in the mainstream space with broadcasters giving it the attention it deserves.
Tags: iss138 | wwc | world cup | spicymango | diversity | John Griffiths
Contributing Author John Griffiths Click to read or download PDF
Make Time for Remapping
Alex Macleod For my 4th Kitplus article I thought I’d highlight an effect in Premiere Pro that frankly I would be lost without. Namely - time remapping.
Tags: iss138 | premiere pro | post production | editing | speed remapping | remapping | mediacity training | Alex Macleod
Contributing Author Alex Macleod Click to read or download PDF
News Out Of The Cloud - Technology At The Front Line Of Journalism
Stuart Almond Throughout history, journalists have always had to seek and adapt to new technologies to deliver news in a format and at a speed that consumers demanded. Today, recent technological changes in the media environment have led to another inflection point. If modern media outlets want to empower journalists to remain agile and turn news stories around quickly and efficiently, they have to start embracing new, innovative technologies, like cloud-based media solutions.
Tags: iss138 | sony | ofcom | cloud-based media | intelligent | Stuart Almond
Contributing Author Stuart Almond Click to read or download PDF
The World of 12G 4K/UHD Processing
Varun Patel Technology moves fast and when it comes to audio and video broadcasting, there is always room for improvements in audio and video quality and ease of production. One of the main goals of broadcasters and content providers today is to create an immersive experience for the viewers, giving them the feeling of being part of the viewed content. The 4K/UHD buzz has been in the consumer world for some time but what does that actually mean for the content producer?
Tags: iss138 | lynx technik | ott | greenmachine | yellobrik | conversion | Varun Patel
Contributing Author Varun Patel Click to read or download PDF