Single-point diamond turning assisted with slow/fast tool servo is a viable technique for complex microlens arrays manufacturing. However, there are still challenges one must overcome when efficiently fabricating discontinuous features. In this study, novel slow-tool-servo method, termed toroid-surface-based slow was proposed generation of discontinuously structured arrays. A discussion on the advantages processing features presented and hexagonal spherical array over large area fabricated...

A novel fabrication method by combining high-speed single-point diamond milling and precision compression molding processes for of discontinuous freeform microlens arrays was proposed. Compared with slow tool servo broaching, selected its flexibility in the true 3D optical surfaces features. The advantage is that surface features can be constructed sequentially spacing axes a virtual spindle at arbitrary positions based on combination rotational translational motions both linear slides. By...

In compression molding of polymer optical components with micro/nanoscale surface features, rapid heating the mold is critical for implementation this technology large-scale applications. Letter, a novel method localized process reported. This based on induction thin conductive coating deposited silicon mold. Since graphene very (∼45 nm), high rate 10∼20°C/s can be achieved by employing 1200 W 30 kHz electrical power unit. Under condition, graphene-coated and substrate heated above polymer's...

Chalcogenide glasses are emerging as enabling materials for low-cost infrared optics due to their transparency in shortwave-to-longwave bands and the possibility be mass produced by precision glass molding (PGM), a near net-shape process. This paper aims evaluate thermoforming mechanism of As40S60 around its transition temperature (Tg) investigate refractive index change residual stresses molded lens during after PGM. First, constitutive model was introduced precisely predict material...

In this research, design, construction, and testing of an innovative Shack–Hartmann sensor are described. As the most critical component, a polymer microlens array is injection molded mounted on board-level CMOS camera such that focal plane camera's image plane. To allow for automatic registration spots measured area, diffusing surface was created at center lens in same diamond machining process uninterrupted operation. This unique does not generate spot. The no-spot feature functions as...

Chalcogenide glasses are emerging as alternative materials for low-cost and high-volume glass molding processes infrared optics. In precision molding, it is well documented that the refractive index variation in molded elements can lead to substantial amounts of aberrations. The has such a significant effect optical designs with lenses need be carefully considered compensated achieve targeted performance. This research aimed evaluate change chalcogenide during process by both finite element...

Silicon is a promising mold material for compression molding because of its properties hardness and abrasion resistance. wafers with carbide-bonded graphene coating micro-patterns were evaluated as molds the fabrication microlens arrays. This study presents an efficient but flexible manufacturing method arrays that combines lapping rapid procedure. Unlike conventional processes microstructures on silicon wafers, such diamond machining photolithography, this research demonstrates unique...

In this study, a novel fabrication process, to the best of our knowledge, was developed fabricate glass harmonic diffractive lens. polymethylmethacrylate master lens machined using single-point diamond turning. Then an electrolytic plating process conducted grow reverse nickel (Ni) mold. Precision compression molding performed Ni mold replicate structures onto surface. Surface measurements and optical testing show that replicated lenses by proposed method have high tolerances require...

Traditional molding and casting processes in optical manufacturing require sophisticated expensive molds equipment. In this work, magnetic liquid droplets were used as soft deformable molds. The drop within an immiscible polymeric resin forms a conical shape at the interface due to equilibrium of magnetostatic force surface tension, which results plano–concave lens after curing. An apparatus was assembled control amplitude gradient field. A Shack-Hartmann sensor employed measure focal length...

Localized rapid heating process utilizing carbide-bonded graphene-coated silicon molds is a high-efficiency and energy-saving technique for high-volume fabrication of polymer optics. The graphene coating used as element because its high thermal conductivity low electrical resistivity. However, the optical property molded dependence on conditions such heat transfer have not been thoroughly investigated. In this research, finite method (FEM) simulation was utilized to interpret temperature...

Injection molding of plastic optical lenses prevails over many other techniques in both efficiency and cost, however polymer shrinkage during cooling, high level uneven residual stresses refractive index variations have limited its potential use for precision fabrication. In this research, we adopted a newly-developed strong graphene network to plain convex fused silica mold surfaces proposed novel injection plano-concave with coated molds. The unique combination the coating substrate...

Fresnel lens arrays are widely employed in concentrator photovoltaics, photonic devices, and integral imaging systems. In this study, a rapid non-isothermal imprinting process for was proposed. process, heated mold with microstructures momentarily pressed onto thermoplastic polymer surface that initially kept at room temperature. The of the can be copied completely to substrate by consecutively until continuous array is obtained. Different from more traditional molding processes, does not...

Single-walled carbon nanotube bundles dispersed in a highly polar fluid are found to agglomerate into porous structure when exposed low levels of laser radiation. The phototunable nanoscale structures provide an unusual way control the acoustic properties suspension. Despite high sound speed nanotubes, measured longitudinal-acoustic waves suspension decreases sharply with increasing bundle concentration. Two possible explanations for this reduction considered. One is simply that because heat...

The majority of optical lenses have spherical surface profiles because they are convenient to fabricate. Replacing optics with aspheric leads smaller size, lighter weight, and less complicated systems a superior imaging quality. However, fabrication is expensive time-consuming. Here, we introduce straightforward low-cost casting method fabricate polymeric lenses. An elastomeric ferrogel was formed into an aspherical profile by using designed magnetic field then used as mold. Different types...