Hot embossing and injection molding for micro-optical components

1997 ◽  
Author(s):  
Mathias Heckele ◽  
Walter Bacher ◽  
Thomas Hanemann ◽  
Heinrich Ulrich
Keyword(s):  
Injection Molding ◽  
Hot Embossing ◽  
Optical Components

Diamond Machinable Sol-Gel Silica Based Hybrid Coatings for High Precision Optical Molds

2010 ◽  
Vol 438 ◽  
pp. 65-72 ◽  
Author(s):  
Andreas Mehner ◽  
Ju An Dong ◽  
Timo Hoja ◽  
Torsten Prenzel ◽  
Yildirim Mutlugünes ◽  
...  
Keyword(s):  
Injection Molding ◽  
High Precision ◽  
Sol Gel ◽  
Processing Parameters ◽  
Hybrid Coatings ◽  
Optical Elements ◽  
Optical Components ◽  
New Approach ◽  
Free Silica ◽  
Gel Processing

The demand for high precision optical elements as micro lens arrays for displays increases continually. Economic mass production of such optical elements is done by replication with high precision optical molds. A new approach for manufacturing such molds was realized by diamond machinable and wear resistant sol-gel coatings. Crack free silica based hybrid coatings from base catalyzed sols from tetraethylorthosilicate (TEOS: Si(OC2H5)4) and methyltriethoxysilane (MTES: Si(CH3)(OC2H5)3) precursors were deposited onto pre-machined steel molds by spin coating process followed by a heat treatment at temperatures up to 800°C. Crack-free multilayer coatings with a total thickness of up to 18 µm were achieved. Micro-machining of these coatings was accomplished by high precision fly cutting with diamond tools. Molds with micro-structured coatings were successfully tested for injection molding of PMMA optical components. The wear resistance of the coatings was successfully tested by injection molding of 1000 PMMA lenses. Hardness and elastic modulus of the coatings were measured by nano indentation. The chemical composition was measured by X-ray photo electron spectroscopy (XPS) as a function of the sol-gel processing parameters.

A New Moiré Grating Fabrication Technique Using Hot Embossing Lithography

2011 ◽  
Vol 83 ◽  
pp. 7-12 ◽  
Author(s):  
Min Jin Tang ◽  
Hui Min Xie ◽  
Jian Guo Zhu ◽  
Peng Wan Chen ◽  
Qing Ming Zhang ◽  
...  
Keyword(s):  
Nanoimprint Lithography ◽  
Hot Embossing ◽  
Fabrication Technology ◽  
Large Area ◽  
Silicon Mold ◽  
Optical Components ◽  
Grating Fabrication ◽  
Multi Scale ◽  
Atomic Force ◽  
Equal Spacing

Moiré grating is a basic optical component, and can be used in various moiré methods. The conventional grating fabrication technology is based on photolithography and holographic interferometry, however, it requires complex optical components and is very difficult to put into practice. In this study, nanoimprint lithography (NIL), or rather, hot embossing lithography (HEL), is proposed for producing high frequency grating. Compared with silicon mold, holographic moiré grating mold costs less and is not easy to break, thus is chosen to be the mold in HEL. Using this mold and the hot embossing system, the grating structure can be transferred to the polymer after HEL process. Through a number of experiments, the process parameters were optimized and gratings were successfully fabricated. The multi-scale morphology of the fabricated gratings was then characterized by scanning electron microscope (SEM), atomic force microscope (AFM) and moiré interferometry. The microscale images observed by AFM and SEM show the regulate dots with equal spacing and the macroscale moiré patterns illuminate the excellent qualities of fabricated grating in a large area. The successful experimental results demonstrate the feasibility of the grating fabricated by HEL for the moiré measurement.

Application of a multilayer injection molding process for thick-walled optical components

2016 ◽  
Vol 36 (6) ◽  
pp. 557-562 ◽  
Author(s):  
Christian Hopmann ◽  
Malte Röbig
Keyword(s):  
Optical Properties ◽  
Injection Molding ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Molding Process ◽  
Optical Components ◽  
Considerable Potential ◽  
Cycle Times ◽  
Molded Part ◽  
Injection Molded

Abstract Nowadays, the injection molding of optical components is becoming more and more important. A process which constructs the injection-molded part in layers offers considerable potential for productivity increases in the manufacturing of thick-walled optical components. The so-called multilayer injection molding, also known as overmolding technology enables a considerable reduction of the normally long cycle times and improves the optical properties. It is even possible to increase the molding accuracy due to the lower shrinkage potential of the single layers. Contrary to experience, the influence of the mold temperature on the bonding strength is very low. So, the temperature control of the mold can be adapted to the process consideration in regard to optical characteristics.

Replication of optical components by hot embossing

2010 ◽  
Author(s):  
M. Worgull ◽  
M. Schneider ◽  
M. Heilig ◽  
A. Kolew ◽  
H. Dinglreiter ◽  
...  
Keyword(s):  
Hot Embossing ◽  
Optical Components

Precision Mould Making – From Macro to Micro

2010 ◽  
Vol 447-448 ◽  
pp. 1-8 ◽  
Author(s):  
Ekkard Brinksmeier ◽  
Jen Osmer
Keyword(s):  
High Surface ◽  
Hot Embossing ◽  
Diamond Turning ◽  
Advanced Materials ◽  
Precision Grinding ◽  
Machining Processes ◽  
Optical Components ◽  
Diamond Machining ◽  
Optical Glasses ◽  
Optical Applications

Nowadays several qualified technologies have been established for the manufacturing of precision moulds. The fields of application can mainly be divided into moulds for non-optical and optical components. For optical moulding inserts the development goes from basic rotational symmetric geometries to complex surfaces like steep aspheres and freeforms which can additionally be overlaid with microstructures. The moulded components require a figure accuracy in the (sub-) micrometer and surface roughness in the nanometer range while moulds for replication also need advanced materials with high surface integrity. Here, diamond machining processes, e.g. diamond turning and milling as well as precision grinding and polishing are necessary for the manufacturing of precision moulding inserts from various materials. Depending on the material and application of the applied part to be replicated different replication techniques are used like injection moulding of plastics, hot embossing and precision moulding of optical glasses. For non-optical applications the current technical progress is driven by miniaturized products which are typically produced in mass production by replication techniques like hot embossing or metal forming. Each of these processes requires specific properties of the mould. Therefore, the surface topography and tribological conditions are of particular importance.

Microfabrication by hot embossing and injection molding at LASTI

2004 ◽  
Vol 10 (10) ◽  
pp. 682-688 ◽  
Author(s):  
H. Mekaru ◽  
T. Yamada ◽  
S. Yan ◽  
T. Hattori
Keyword(s):  
Injection Molding ◽  
Hot Embossing

Nanoreplication in polymers using hot embossing and injection molding

2000 ◽  
Vol 53 (1-4) ◽  
pp. 171-174 ◽  
Author(s):  
H. Schift ◽  
C. David ◽  
M. Gabriel ◽  
J. Gobrecht ◽  
L.J. Heyderman ◽  
...  
Keyword(s):  
Injection Molding ◽  
Hot Embossing
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