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
An Epiphany Moment
Peter Savage 2 I had been negotiating the sale of my company and had reached the really hard end of the bargain. We were close to agreeing the final sum after a lot of too-much-give-and-not-enough-take negotiation. The solicitors were calling me, keen for a deal. It had come down to one sticking point and, in my hard ball “I am the Wolf of Wall Street” guise, I wasn’t going to let it go. It would make a value difference of 1.5% on the total outcome. Not much, you might think, but I had already nearly fallen out with the solicitors over their fees and I was giving my advisors an extremely hard time because the corporate adviser couldn’t see how I had already given more than an inch and the buyers were taking more than a mile. I was not going to let them win.
Tags: iss134 | azule | finance | Peter Savage 2
Contributing Author Peter Savage 2 Click to read or download PDF
Using Wireless Transmission
Jeremy Benning Wireless acquisition is a staple of live sports, entertainment and reality shows where cable free capture permits shots not previously possible, for health and safety reasons, and gives the camera-operator greater artistic licence to roam. The same is increasingly true of narrative drama where cinematographers are keen to work handheld or Steadicam where that helps tell the story. Any equipment which frees their movement and time by being lighter, easier to use and reliable in performance is going to tick a lot of boxes.
Tags: iss134 | wireless | 4k | transmission | Jeremy Benning
Contributing Author Jeremy Benning Click to read or download PDF
Shedding Light on the Blackmagic Pocket Cinema Camera 4k BMCPP4K
Garth de Bruno Austin “What is it about light that has us craving it?” Is the question asked in the opening seconds of Garth de Bruno Austin’s latest short, The Colour of Light. Exploring this natural, human need as well as our innate desire to control it, Garth’s film showcases everyday people going about their lives in differing degrees of luminance, whether that be an artificial streetlight or a natural morning sunrise.
Tags: iss134 | blackmagic | cinema camera | 4k | cpp4k | Garth de Bruno Austin
Contributing Author Garth de Bruno Austin Click to read or download PDF
The brave new world of software based production
Boromy Ung In today’s rapidly evolving broadcast industry, the only constant media organizations can truly count on is change — and the need to adapt as rapidly and cost-effectively as possible. One of the biggest agents of change is the IP revolution, driving broadcasters to migrate their operations to all-software solutions running on commodity, IT-based technologies.
Tags: iss134 | chyronhego | graphics | sports | ott | Boromy Ung
Contributing Author Boromy Ung Click to read or download PDF
Sony HDC-4800 Review
Andy McKenzie First announced at NAB 2016, the Sony HDC-4800 is a studio camera system capable of shooting 4K/UHD at up to 8x or full HD at up to 16x. With a price point upwards of £250,000 it is a very high-end product with a wide feature set. In Sony's own words, "This is the future of live production, designed to satisfy the storytelling aspect of modern sports production.” Deliveries began in mid 2017 and, after careful preliminary evaluation, we invested in several systems for our hire fleet ahead of the FIFA World Cup in Russia.
Tags: iss134 | review | hdc-4800 | sony | finepoint | Andy McKenzie
Contributing Author Andy McKenzie Click to read or download PDF