研究目的
Investigating a new process chain for the fabrication of curved micro-structured optical elements by injection compression molding.
研究成果
The proposed process chain enables the fabrication of curved DOEs with high quality. The LDW process is suitable for creating curved master substrates, and the electroplating and injection compression molding processes accurately transfer the micro-structures. The resulting DOEs have high optical efficiency and can potentially replace expensive conventional elements.
研究不足
The LDW process is limited by the maximum local surface slope angle which is in the region of 15°. The maximum DOE step height which can be realized is limited to approximately 5 μm. The electroplating process showed significant variations in the resulting nickel thickness due to inhomogeneous electrical fields.
1:Experimental Design and Method Selection:
The process chain includes laser direct writing (LDW) on curved glass substrates, electroplating to create a nickel stamper, and injection compression molding to replicate the optical elements.
2:Sample Selection and Data Sources:
A plano-convex N-BK7 glass lens with a radius of curvature of
3:5 mm was used as the substrate. List of Experimental Equipment and Materials:
CLWS300 polar coordinate LDW system, MicroChem AZ 1805 photoresist, Norland NOA81 UV glue, Trogamid myCX molding material.
4:Experimental Procedures and Operational Workflow:
The process involves LDW lithography, electroplating to create a mold insert, and injection compression molding to replicate the DOEs.
5:Data Analysis Methods:
Characterization was performed using atomic force microscopy (AFM), white light interferometry (WLI), and confocal measurement setup.
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