Thank you for your interesting account. Personally, in my working days in the Micrographic industry, I had the opportunity to visit Leica's Singapore factory and I was impresssed with their precision especially when a lens' drawing needed to be printed by the microfilm enlarger printed I was selling. Microfilm resolution at 240LP/mm for drawings way surpassed today's Zeiss lens(ZE 50f1.4) resolving power of only 45LP/mm. To make an A0 or A1 size print from such high resolution microfilm was no easy task and by golly how stringent they were. So I understand why a Leica lens is so good even by today's standard.
Hi,
2 years ago I had the priviledge of visiting the Leica facility in Switzerland as part of my work and had the rare opportunity to visit the factory where lens are made.
As we toured the facility the guide explained how the optics are made. This is what I remember:
They use only pure silica and not recycled glass. The silica melted down and cast into cylindrical blocks (about 1m tall and 300-500mm diameter. These blocks are then left to cool naturally in a special room. Believe it or not, it takea bout 3 years for the blocks to cool. As glass is not actually a solid but a when cooled its actually in a solidified liquid state, by allowing it to naturally cool it will ensure unniformity in density and clarity.
After 3 years the blocks are taken out, the end portions cut away and only middle sections are use to cut them into smaller discs. I did not believe this but they told me they would cut 3 discs from 3 different blocks just to make 1 lens. So these discs go through a mechanical cutting and grinding process to get it to the desired size. Final stage is handpolished by a mastercraftsman.
I was fortunate enough to talk with one of these people a 50 plus year old Swiss guy. He told me his apprenticeship took 15 years! I was like wow that's a long time for probation. Polishing a lens depending on the curvature and diameter can take anywhere from hours to days. The larger ones are used in high end surveying and arial photography/scanning.
Coming back to the 3 discs, after they finish a lens they will check the lens for clarity and other specifics of the glass. Should this fail then the entire batch of lens from this block will be discarded.
I guess what i learnt from that trip is... the lens manufacture for them is more of a coach building process and there's a lot of wastage.
Anyway, this is what I can clearly remember and I thought I share my experience. So please do not quote me on this.