Mechanic Lens/Prism Grinding

ITI Mechanic Lens/Prism Grinding Syllabus (English)

Course Overview

• Trade Name: Mechanic Lens/Prism Grinding
• Duration: 1 Year (2 Semesters)
• NSQF Level: Level 4
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in precision grinding, polishing, and shaping of lenses and prisms for optical devices, equipping them for roles as lens grinders, optical technicians, or quality inspectors in optical manufacturing, eyewear industries, or scientific instrument production, or for self-employment in lens/prism fabrication services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Optics: Basics of light, refraction, reflection; role of lenses/prisms in optical systems.
• Safety Practices: Workshop safety, PPE (goggles, gloves, dust masks), handling glass, chemical safety, first aid.
• Workshop Tools: Vernier calipers, micrometers, lens gauges, files, chisels; usage and maintenance.
• Optical Materials: Types of glass (crown, flint), properties, handling brittle materials.
• Grinding Basics: Grinding machines, abrasives (diamond, carborundum), grain sizes, wheel selection.
• Lens Types: Convex, concave, cylindrical, prismatic lenses; applications in spectacles, telescopes, microscopes.
• Engineering Drawing: Reading lens/prism blueprints, curvature diagrams, tolerance specifications.

Trade Practical

• Safety Drills: Using PPE, handling glass safely, practicing dust control, emergency procedures.
• Tool Handling: Measuring with vernier calipers/micrometers, filing glass edges, setting up grinding tools.
• Basic Grinding: Grinding flat glass surfaces, achieving accuracy (±0.25mm), using coarse abrasives.
• Lens Cutting: Cutting lens blanks using format cutting machines, marking for curvature.
• Surface Preparation: Smoothing ground surfaces, inspecting for scratches or pits.
• Measurement Practice: Checking lens thickness, curvature with lens gauges, verifying tolerances.
• Project Work: Grinding a flat glass mirror to specified finish and accuracy.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Advanced Grinding: Curve generation, spherical/aspherical lens grinding, prism angle precision.
• Polishing Techniques: Polishing compounds (cerium oxide), hand polishing, machine polishing.
• Optical Instruments: Lens use in telescopes, microscopes, binoculars, periscopes; optical aberrations.
• Coating Processes: Anti-reflective coatings, cementing lenses, fusion techniques.
• Quality Control: Surface quality standards, interferometry, lensometer usage, ISO tolerances.
• Maintenance: Servicing grinding/polishing machines, aligning spindles, replacing abrasives.
• Entrepreneurship: Starting a lens grinding workshop, costing, market trends in optics.

Trade Practical

• Curve Grinding: Grinding convex/concave lenses, maintaining curvature (±0.1mm).
• Prism Grinding: Shaping prisms to precise angles, ensuring flatness and clarity.
• Polishing Tasks: Polishing lenses/prisms to optical clarity, using cerium oxide slurries.
• Coating Application: Applying anti-reflective coatings, cementing lens pairs, testing adhesion.
• Instrument Work: Assembling lenses into frames, testing with lensometers for focal length.
• Quality Inspection: Measuring surface quality with interferometers, documenting defects.
• Project Work: Producing a spectacle lens or prism with grinding, polishing, and coating.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Lens focal length, curvature radius, abrasive consumption, polishing time.
  • Science: Optics (Snell’s law, refractive index), material stress, thermal effects in grinding.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Lens/prism cross-sections, optical system layouts, coating diagrams.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical reporting, client interaction, teamwork.
  • IT Literacy: Using lens design software, online optical resources, quality control tools.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like lens grinding, prism shaping, polishing, quality checks.
• Evaluation Criteria: Grinding accuracy, surface quality, safety adherence, optical performance.
• Certification: NCVT National Trade Certificate (NTC) upon passing both semesters, globally recognized.

Career Opportunities

• Employment: Lens grinder, optical technician, quality inspector in optical manufacturing, eyewear production, or scientific instrument industries.
• Self-Employment: Lens/prism grinding workshop, optical repair services, consultancy for optical firms.
• Further Studies: Diploma in Optical Engineering, certifications in precision optics or metrology.