|
|
Micro-optical fabrication by ultraprecision diamond machining and precision molding |
Hui LI1, Likai LI1,2, Neil J. NAPLES1, Jeffrey W. ROBLEE3, Allen Y. YI1( ) |
1. Department of Integrated System Engineering, The Ohio State University, Columbus, OH 43210, USA 2. Nistica Inc., Bridgewater, NJ 08807, USA 3. Ametek Precitech, Keene, NH 03431, USA |
|
|
Abstract Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression molding or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultraprecision machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.
|
Keywords
ultraprecision machining
slow tool servo
fast tool servo
compression molding
injection molding
microlens arrays
optical fabrication
|
Corresponding Author(s):
Allen Y. YI
|
Just Accepted Date: 01 April 2017
Online First Date: 24 April 2017
Issue Date: 19 June 2017
|
|
1 |
AMETEK Precitech Inc. Precitech white paper directory. 2016. Retrieved from Precitech website
|
2 |
K Fuerschbach, J P Rolland, K P Rolland-Thompson. Realizing freeform: A LWIR imager in a spherical package. In: Renewable Energy and the Environment. OSA, 2013, FW1B.2
https://doi.org/10.1364/FREEFORM.2013.FW1B.2
|
3 |
AMETEK Precitech Inc. Slow tool servo. 2016. Retrieved from Precitech website
|
4 |
AMETEK Precitech Inc. Adaptive control technology. 2016. Retrieved from Precitech website
|
5 |
Y Chen. Thermal forming process for precision freeform optical mirrors and micro glass optics. Dissertation for the Doctoral Degree. Columbus: The Ohio State University, 2010
|
6 |
H Zhang, S Scheiding, L Li, et al. Manufacturing of a precision 3D microlens array on a steep curved substrate by injection molding process. Advanced Optical Technologies, 2013, 2(3): 257–268
https://doi.org/10.1515/aot-2012-0061
|
7 |
Levicron. Ultra-precision meets CNC performance. Retrieved from Levicron website
|
8 |
H Mohammadi, D Ravindra, S K Kode, et al. Experimental work on micro laser-assisted diamond turning of silicon (111). Journal of Manufacturing Processes, 2015, 19: 125–128
https://doi.org/10.1016/j.jmapro.2015.06.007
|
9 |
F Klocke, O Dambon, B Bulla. Diamond turning of aspheric steel molds for optics replication . SPIE Proceedings, Micromachining and Microfabrication Process Technology XV, 2010, 7590: 75900B
https://doi.org/10.1117/12.839422
|
10 |
D E Brehl, T A Dow. Review of vibration-assisted machining. Precision Engineering, 2008, 32(3): 153–172
https://doi.org/10.1016/j.precisioneng.2007.08.003
|
11 |
A Y Yi, A Jain. Compression molding of aspherical glass lenses—A combined experimental and numerical analysis. Journal of the American Ceramic Society, 2005, 88(3): 579–586
https://doi.org/10.1111/j.1551-2916.2005.00137.x
|
12 |
F Wang, Y Chen, F Klocke, et al. Numerical simulation assisted curve compensation in compression molding of high precision aspherical glass lenses. Journal of Manufacturing Science and Engineering, 2009, 131(1): 011014
https://doi.org/10.1115/1.3063652
|
13 |
Opli Inc. Mobile phone objective camera optical design. 2016. Retrieved from Opli website
|
14 |
M Schaub, J Schwiegerling, E Fest, et al. Molded Optics: Design and Manufacture. Boca Raton: CRC Press, 2016
|
15 |
F C Wippermann, E Beckert, P Dannberg, et al. Disposable low cost video endoscopes for straight and oblique viewing direction with simplified integration. SPIE Proceedings, Design and Quality for Biomedical Technologies III, 2010, 7556: 755607
https://doi.org/10.1117/12.840692
|
16 |
H Li. Design, fabrication and evaluation of nonconventional optical components. Dissertation for the Doctoral Degree. Columbus: The Ohio State University, 2016
|
17 |
N W Kim, K W Kim, H C Sin. Finite element analysis of low temperature thermal nanoimprint lithography using a viscoelastic model. Microelectronic Engineering, 2008, 85(9): 1858–1865
https://doi.org/10.1016/j.mee.2008.05.030
|
18 |
U Greis, G Kirchhof. Injection molding of plastic optics. SPIE Proceedings, Optical Surface Technology, 1983, 381(6): 69–77
https://doi.org/10.1117/12.934843
|
19 |
T Maruyama, H Kabe. Sink mark phenomenon of injection-molding plastics. Kobunshi Ronbunshu, 1981, 38(4): 275–278
https://doi.org/10.1295/koron.38.275
|
20 |
L Su, A Y Yi. Finite element calculation of refractive index in optical glass undergoing viscous relaxation and analysis of the effects of cooling rate and material properties. International Journal of Applied Glass Science, 2012, 3(3): 263–274
https://doi.org/10.1111/j.2041-1294.2011.00074.x
|
21 |
O Dambon, F Wang, F Klocke, et al. Efficient mold manufacturing for precision glass molding. Journal of Vacuum Science & Technology B, Nanotechnology and Microelectronics: Materials, Processing, Measurement, and Phenomena, 2009, 27(3): 1445–1449
https://doi.org/10.1116/1.3056171
|
22 |
F Wang, Y Chen, F Klocke, et al. Numerical simulation assisted curve compensation in compression molding of high precision aspherical glass lenses. Journal of Manufacturing Science and Engineering, 2009, 131(1): 011014
https://doi.org/10.1115/1.3063652
|
23 |
M Huenten, D Hollstegge, F Wang, et al. Wafer level glass optics: Precision glass molding as an alternative manufacturing approach. SPIE Proceedings, Advanced Fabrication Technologies for Micro/Nano Optics and Photonics IV, 2011, 7927: 79270L
https://doi.org/10.1117/12.873169
|
24 |
A I Isayev. Orientation development in the injection molding of amorphous polymers. Polymer Engineering and Science, 1983, 23(5): 271–284
https://doi.org/10.1002/pen.760230507
|
25 |
S W Kim, L S Turng. Three-dimensional numerical simulation of injection molding filling of optical lens and multiscale geometry using finite element method. Polymer Engineering and Science, 2006, 46(9): 1263–1274
https://doi.org/10.1002/pen.20585
|
|
Viewed |
|
|
|
Full text
|
|
|
|
|
Abstract
|
|
|
|
|
Cited |
|
|
|
|
|
Shared |
|
|
|
|
|
Discussed |
|
|
|
|