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a. The first step in manufacturing any mirror is cutting the outline of the glass "blank" to suit the application. If the mirror is for an automobile, for example, the glass will be cut out to fit in the mirror mount on the car. Very hard, finely pointed blades are used to do the cutting. Diamond scribes or saws, sharp metal points with diamond dust embedded in them, are often used because the diamond will wear down the glass. Cutting is usually done before the metal coating because the coating may flake off the glass as a result of the cut. An alternative for cutting the glass to form blanks is to mold the glass in its molten state.
b. Blanks are then placed in optical grinding machines. The blank-filled base is placed against another metal plate with the desired surface shape flat, convex, or concave. A grinding compound, a gritty liquid, is spread over the glass blanks as they are rubbed or rolled against the curved surface. Finer and finer grits are used until the surface is very smooth and even.
c. When the glass surfaces are shaped appropriately and polished to a smooth finish, they are coated with whatever reflective material the designer has chosen. Regardless of the coating material, it is applied in an apparatus called an evaporator. The method of coating creates very uniform and highly reflective surfaces.
d. Several evaporation steps are then combined to make a multiple-layer coating. Clear dielectric materials may be evaporated on top of metal or other dielectrics to change the reflective or mechanical properties of a surface. Mirrors with silvering on the back of the glass, for instance, often have an opaque dielectric layer applied to improve the reflectivity and keep the metal from scratching. One-way mirrors are the exception to this procedure, in which case great care must be taken not to damage the thin metal coating.
e. Finally, when the proper coatings have been applied, the finished mirror is mounted in a base or packed carefully in a shock resistant package for shipping.
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Last Update: Tue, 18 Apr 23