Design And Fabrication Of Nonconventional Optical Components By Precision Glass Molding
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Design And Fabrication Of Nonconventional Optical Components By Precision Glass Molding
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Author : Peng He
language : en
Publisher:
Release Date : 2014
Design And Fabrication Of Nonconventional Optical Components By Precision Glass Molding written by Peng He and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2014 with categories.
Precision glass molding is a net-shaping process to fabricate glass optics by replicating optical features from precision molds to glass at elevated temperature. The advantages of precision glass molding over traditional glass lens fabrication methods make it especially suitable for the production of optical components with complicated geometries, such as aspherical lenses, diffractive hybrid lenses, microlens arrays, etc. Despite of these advantages, a number of problems must be solved before this process can be used in industrial applications. The primary goal of this research is to determine the feasibility and performance of nonconventional optical components formed by precision glass molding. This research aimed to investigate glass molding by combing experiments and finite element method (FEM) based numerical simulations. The first step was to develop an integrated compensation solution for both surface deviation and refractive index drop of glass optics. An FEM simulation based on Tool-Narayanaswamy-Moynihan (TNM) model was applied to predict index drop of the molded optical glass. The predicted index value was then used to compensate for the optical design of the lens. Using commercially available general purpose software, ABAQUS, the entire process of glass molding was simulated to calculate the surface deviation from the adjusted lens geometry, which was applied to final mold shape modification. A case study on molding of an aspherical lens was conducted, demonstrating reductions in both geometry and wavefront error by more than 60%.
Fabrication Of Complex Optical Components
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Author : Ekkard Brinksmeier
language : en
Publisher: Springer Science & Business Media
Release Date : 2012-09-14
Fabrication Of Complex Optical Components written by Ekkard Brinksmeier and has been published by Springer Science & Business Media this book supported file pdf, txt, epub, kindle and other format this book has been release on 2012-09-14 with Technology & Engineering categories.
High quality optical components for consumer products made of glass and plastic are mostly fabricated by replication. This highly developed production technology requires several consecutive, well-matched processing steps called a "process chain" covering all steps from mold design, advanced machining and coating of molds, up to the actual replication and final precision measurement of the quality of the optical components. Current market demands for leading edge optical applications require high precision and cost effective parts in large volumes. For meeting these demands it is necessary to develop high quality process chains and moreover, to crosslink all demands and interdependencies within these process chains. The Transregional Collaborative Research Center "Process chains for the replication of complex optical elements" at Bremen, Aachen and Stillwater worked extensively and thoroughly in this field from 2001 to 2012. This volume will present the latest scientific results for the complete process chain giving a profound insight into present-day high-tech production.
Design Fabrication And Evaluation Of Nonconventional Optical Components
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Author : Hui Li
language : en
Publisher:
Release Date : 2016
Design Fabrication And Evaluation Of Nonconventional Optical Components written by Hui Li and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2016 with categories.
The main focus of this dissertation is to seek scientific and fundamental knowledge of nonconventional optical components including its optical design, ultraprecision prototyping, precision molds making, transition into industrial production and efficient evaluation. A nonconventional component in this dissertation is loosely defined as an optical component either that is not symmetric around its optical axis or that is aspherical surface with three or higher order coefficient. Nonconventional optics have broadened the vision of optical designers and enhanced the design flexibility and thus are becoming increasingly important as a core next-generation optical component. These optical components have gradually been implemented to replace conventional spherical and aspherical counterparts in the fields of imaging (Plummer, 1982), illumination (Fournier & Rolland, 2008), aviation (Spano, 2008) , and energy (Zamora, et al., 2009) where freeform optics have demonstrated excellent optical performance and high degree of system integration. However, design, fabrication and metrology of nonconventional optics have not been developed at the same pace. Due to the complex nature of nonconventional optics manufacturing processes, the production efficiency and finished quality of nonconventional optical components are difficult to be improved. To validate optical performance, in this dissertation ultraprecision diamond tooling is applied to prototype the optical design, which is capable of generating precision optical features both on polymer blank and metal mold without post grinding and polishing process. In addition, the prototyping process also paves the way to mold fabrication. To produce low cost high volume high quality nonconventional optical components, precision compression/microinjection molding has been combined with ultraprecision diamond machining and cleanroom manufacturing respectively for different size scale and application. Once the low cost molded nonconventional optical components and assembly are fabricated, their optical performance needs to be characterized to ensure quality in industrial production. The geometric feature and principle optical parameter, such as focal length, are two important aspects that influence the final optical performance considerably. In order to solve the major problems in manufacturing affordable high quality nonconventional optical components, this dissertation will include several key steps: 1) Investigate nonconventional optics design that could be functionally and economically applied in various optical components or systems to further improve their performance; 2) Validate and evaluate nonconventional optics design by ultraprecision prototyping; 3) Develop the precision molds manufacturing process and the corresponding molding process both for miniaturized lens profile and micro scale diffraction structure; 4) Investigate the products quality by crucial optical parameters measurement and surface profiling. Overall, this dissertation describes a comprehensive understanding of low cost high volume nonconventional optics manufacturing.
Fabrication Of Precise Optical Components Using Electroforming Process And Precision Molding
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Author : Abolfazl Zolfaghari
language : en
Publisher:
Release Date : 2021
Fabrication Of Precise Optical Components Using Electroforming Process And Precision Molding written by Abolfazl Zolfaghari and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2021 with Electroforming categories.
Applications of precise optical components with complex shapes are becoming more popular because of demands for more accurate, smaller size optical components. Although fabrication techniques of the components have advanced in recent years, only molding based methods are typically suitable for mass production. On the other hand, molding based methods are less capable of creating complex optical components. To deal with these limitations, a process based on nickel electroforming is introduced to replicate mold inserts directly from a plastic optical component, which itself can be fabricated by any fabrication methods with high flexibility. Then, using the plated mold insert in precision compression molding, the optical components are replicated. To investigate replication capabilities of the developed method in fabrication of plastic optical components, a polymethylmethacrylate (PMMA) microlens array was replicated to a nickel-plated mold first from another plastic microlens array then mass-produced using compression molding process. Properties of both microlens arrays, were investigated for geometrical accuracy, surface quality, and optical performance. The results demonstrated a promising technique to manufacture plastic optical component with high production rates. Fabrication capabilities of the method in production of infrared optics was also evaluated through producing an infrared microlens array from a plastic microlens array. Comparison between the fabricated infrared microlens array and the plastic microlens array in terms of geometry, surface quality, and optical performance has shown that it is a promising technique for replicating infrared microlens arrays. Using the developed method, a new fabrication method of non-planar optical component with large area was also proposed and demonstrated by producing micro feature on a cylindrical surface. The technique was capable to transfer micro-optical features from a planar surface, which is much easier to produce, to non-planar surfaces. To assess possibility of fabricating complex glass optical surfaces using the developed fabrication technique, a nickel mold of diffractive harmonic diffractive lens (HDL) from a plastic HDL was made. Then, the mold and precision compression molding were used to fabricate glass harmonic diffractive lens. Geometrical analysis and optical performance of the plastic and the fabricated HDL showed that the method is capable to be used in fabrication of precision glass optics as well. Precision compression molding is one of the most suitable mass production methods of optical components with micro/nanoscale surface features. This process suffers from long heating and cooling cycles. To deal with the challenge, a novel precision compression molding was proposed. In the proposed process, induction heating of a thin nickel mold insert is used. In the process, the nickel mold insert is replicated from a plastic optical component as described before. To evaluate cooling and heating cycles of the method, a numerical model of the heating system using finite element method (FEM) was created and run in this research. According to simulation results, heating and cooling rates were significantly improved. Geometrical analysis and optical performance evaluation of the replicated microlens array have shown that the proposed fabrication method has a potential to reduce the problems of conventional bulk heating system.
Precision Lens Molding Of Glass A Process Perspective
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Author : Jayson J. Nelson
language : en
Publisher: Springer Nature
Release Date : 2020-04-10
Precision Lens Molding Of Glass A Process Perspective written by Jayson J. Nelson and has been published by Springer Nature this book supported file pdf, txt, epub, kindle and other format this book has been release on 2020-04-10 with Technology & Engineering categories.
This book highlights the tools and processes used to produce high-quality glass molded optics using commercially available equipment. Combining scientific data with easy-to-understand explanations of specific molding issues and general industry information based on firsthand studies and experimentation, it provides useful formulas for readers involved in developing develop in-house molding capabilities, or those who supply molded glass optics. Many of the techniques described are based on insights gained from industry and research over the past 50 years, and can easily be applied by anyone familiar with glass molding or optics manufacturing. There is an abundance of information from around the globe, but knowledge comes from the application of information, and there is no knowledge without experience. This book provides readers with information, to allow them to gain knowledge and achieve success in their glass molding endeavors.
Fabrication Of Complex Optical Components
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Author : Ekkard Brinksmeier
language : en
Publisher: Springer Science & Business Media
Release Date : 2012-09-13
Fabrication Of Complex Optical Components written by Ekkard Brinksmeier and has been published by Springer Science & Business Media this book supported file pdf, txt, epub, kindle and other format this book has been release on 2012-09-13 with Technology & Engineering categories.
High quality optical components for consumer products made of glass and plastic are mostly fabricated by replication. This highly developed production technology requires several consecutive, well-matched processing steps called a "process chain" covering all steps from mold design, advanced machining and coating of molds, up to the actual replication and final precision measurement of the quality of the optical components. Current market demands for leading edge optical applications require high precision and cost effective parts in large volumes. For meeting these demands it is necessary to develop high quality process chains and moreover, to crosslink all demands and interdependencies within these process chains. The Transregional Collaborative Research Center "Process chains for the replication of complex optical elements" at Bremen, Aachen and Stillwater worked extensively and thoroughly in this field from 2001 to 2012. This volume will present the latest scientific results for the complete process chain giving a profound insight into present-day high-tech production.
Investigation Of Optical Effects Of Chalcogenide Glass In Precision Glass Molding And Applications On Infrared Micro Optical Manufacturing
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Author : Lin Zhang
language : en
Publisher:
Release Date : 2019
Investigation Of Optical Effects Of Chalcogenide Glass In Precision Glass Molding And Applications On Infrared Micro Optical Manufacturing written by Lin Zhang and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2019 with Micromachining categories.
Precision glass molding (PGM) is being considered as an alternative to traditional methods of manufacturing large-volume, high-quality and low-cost optical components. In this process, glass optics is fabricated by replicating optical features from precision molds to glass at elevated temperature. Chalcogenide glasses are emerging as alternative infrared materials for their wide range infrared transmission, high refractive index and low phonon energy. In addition, chalcogenide glasses can be readily molded into precision optics at elevated temperature, slightly above its glass transition temperature (Tg), which in general is much lower compared to oxide glasses. The primary goal of this research is to evaluate the thermoforming mechanism of chalcogenide glass around Tg and investigate its refractive index change and residual stresses in molded lens in and post PGM. Firstly, a constitutive model is introduced to precisely predict the material behavior in PGM by integrating subroutines into a commercial finite element method (FEM) software. This modeling approach utilizes the Williams-Landel-Ferry (WLF) equation and Tool-Narayanaswamy-Moynihan (TNM) model to describe (shear) stress relaxation and structural relaxation behaviors, respectively. It is predicted that `index drop’ occurred inside the molded prism due to rapid thermal cycling and the cooling rate above Tg can introduce large geometry deviations to the molded optical lens. Secondly, the refractive index variations inside molded lenses are further evaluated by measuring deviation angle through a prism & wavefront changes through molded lens using a Shack-Hartmann wavefront sensor (SHS), while the residual stresses trapped inside the molded lenses are obtained by using a birefringence method. Measured results of the molded infrared lenses combining numerical simulation provide an opportunity for optical manufacturers to achieve a better understanding of the mechanism and optical performance variation of chalcogenide glasses in and post PGM. Upon completion of the aforementioned research, two typical micro IR optics are designed, fabricated and tested, an infrared SHS and a large field-of-view (FOV) microlens array, as demonstrations. A novel fabrication method combining virtual spindle based high-speed single-point diamond milling and PGM process is adopted to fabricate infrared microlens array. The uniqueness of the virtual spindle based single-point diamond milling is that the surface features can be constructed sequentially by spacing the virtual spindle axis at an arbitrary position based on a combination of rotational and transitional motions of the machine tool. After the mold insert is machined, it is employed to replicate the optical profile onto chalcogenide glass. On the other hand, an infrared compound-eye system consisting of 3×3 channels for a FOV of 48°×48° is developed. The freeform microlens array on a flat surface is utilized to steer and focus the incident light from all three dimensions (3D) to a two-dimension (2D) infrared imager. Using raytracing, the profiles of the freeform microlenses of each channel are optimized to obtain the best imaging performance. To avoid crosstalk among adjacent channels, a micro aperture array fabricated by 3D printing is mounted between the microlens array and IR imager. The imaging tests of the infrared compound-eye imaging system show that the asymmetrical freeform lenslets are capable of steering and forming legible images within the design FOV. Compared to a conventional infrared camera, this novel microlens array can achieve a considerably larger FOV while maintaining low manufacturing cost without sacrificing image quality. Finally, two rapid heating processes are explored and demonstrated by using graphene-coated silicon as an effective and high-performance mold material for precision glass molding. One process is based on induction heating and the other one is based on mid-infrared radiation. Since the graphene coating is very thin (~45 nm), a high heating rate of 5~20 °C/s can be achieved. The contact surface of the Si mold and the polymer substrate can be heated above the Tg within 20 s and subsequently cooled down to room temperature within tens of seconds after molding. The feasibility of this process is validated by the fabrication of optical gratings, micropillar matrices, and microlens arrays on polymethylmethacrylate (PMMA) substrate with high precision. The uniformity and surface geometries of the replicated optical elements are evaluated using an optical profilometer. Compared with conventional bulk heating molding process, this novel rapid localized heating process could improve replication efficiency with better geometrical fidelity.
Development Of Advanced Design And Fabrication Of Non Conventional Optical Components In Parallel With The Development Of A Tool For Nanolithography
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Author : Noach Salman
language : en
Publisher:
Release Date : 2001
Development Of Advanced Design And Fabrication Of Non Conventional Optical Components In Parallel With The Development Of A Tool For Nanolithography written by Noach Salman and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2001 with categories.
Design Fabrication And Applications Of Precision Plastic Optics
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Author : Xiaohui Ning
language : en
Publisher: SPIE-International Society for Optical Engineering
Release Date : 1995
Design Fabrication And Applications Of Precision Plastic Optics written by Xiaohui Ning and has been published by SPIE-International Society for Optical Engineering this book supported file pdf, txt, epub, kindle and other format this book has been release on 1995 with Science categories.
Innovation In Production Of Products For Micro Optics
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Author : Inés Ferrer Real
language : en
Publisher:
Release Date : 2010-11-01
Innovation In Production Of Products For Micro Optics written by Inés Ferrer Real and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2010-11-01 with Education categories.
This book has been prepared as part of the Training activities in the frame of the EU funded project Production4micro (FP6-IP-026765-2). Ascamm, as coordinator of the workpackage for Training, has compiled all the documents and information received from the partners.\n \n Production4μ key knowledge areas are reflected in this book:\n Developments in tool making process chain for the tools needed for precision glass molding and micro injection of plastic, with particular emphasis on high reliability, high quality, short delivery times and long tool life times.High precision glass molding technology and micro injection of plastics for the large-volume production of complex shaped and structured high-precision optic parts.Process Integrated Quality Assurance by the achievement of a stable replication process for optical components through a comprehensive measurement technology.Production Planning, Launch and Quality Management: Innovative solutions to support the industrial partners in their production planning. Models and methodologies supporting knowledge transfer, cost calculation, production planning and inspection as well as quality management.