In an example of creativity and resourcefulness, one of our teams at Iridian Spectral Technologies – a unit of IDEX specializing in designing and manufacturing thin-film, multi-layer high-performance filter optics – recently completed a remarkable rebuild of a Blanchard rotary surface grinder—transforming a decades-old, non-functional machine into a modern, production-ready asset.
The project began quietly in late 2022 when the control system of an early- ‘90s Blanchard unit failed. With no immediate need to bring it back online, the team initiated a low-priority effort to explore the feasibility of a full control system rebuild. The team drafted a preliminary design and ordered core components. They made initial progress, but soon paused the project. It remained that way until a second Blanchard unit failed earlier this year, prompting a shift in priorities.
What followed was a two-week sprint of innovation to refurbish the polishing machine. The team removed the outdated control system and servo, replacing them with a modern setup featuring a new servo, Programmable Logic Controller (PLC), and touch panel. Custom mounting plates and a replacement timing gear were fabricated to integrate the new components seamlessly. By the end of the second week, the machine was running a fully automatic grind cycle.
However, the journey didn’t stop there. A failed bearing in the main grinding motor posed another challenge. Historically, these specialized conical bearings were costly and slow to source. Demonstrating true ingenuity, the team located an identical alternative for a fraction of the cost—and had them delivered within 24 hours. After a careful motor rebuild, the machine passed testing and completed its first successful grind.
A particularly exciting discovery during the rebuild was a plate indicating the machine originally belonged to Semrock now part of IDEX Health & Science—adding a layer of history to this upcycling success story.
Fine-tuning continued with precision shimming of the cutting head and magnetic chuck, reducing part wedge from 130μm to just 5μm. The machine was released to production shortly after and has since been running reliably, producing high-quality parts with minimal variation.
Beyond restoring a pivotal machine, this project has broader benefits. A new grinder is about $250-300K USD. This upcycling project took three weeks and cost $5K USD. Additionally, the team now has a flexible, in-house control system compatible with most Blanchard 8AD-12 units. This opens the door to future upgrades and salvaging efforts, offering a cost-effective alternative to purchasing new equipment while enhancing customization and workflow efficiency.
Based in Ottawa, Canada, Iridian Spectral Technologies is a global leader in designing and manufacturing thin-film, multi-layer high-performance filter optics.