Method of manufacturing a replication mold for an optical element

Abstract

A method of manufacturing a mold for manufacturing an optical element is provided. Precision material deposition techniques, such as three-dimensional printing, for example, masters for fabricating optical elements on a substrate are used. Next, a master mold part is manufactured by casting a mold material on the deposited master. The master mold part is used to produce a master copy by casting a master copy substance in a cavity of a master mold. The master replicating species may be different from the master species. Next, a replicated mold part is manufactured by casting a mold material on the master replica. The replicated mold part is preferably part of a larger mold having two or more parts and is used to manufacture an optical element by combining the mold parts to provide a cavity for casting of the optical element.

Description

Technical Field

[0001] The various aspects and their implementations relate to the manufacture of optical elements and molds for casting such optical elements. Background Technology

[0002] Various methods for manufacturing optical components and molds are known. It is important that any master object used to manufacture actual products has good and robust quality, enabling it to be stored for a longer period of time without any significant risk of deterioration. Summary of the Invention

[0003] Certain materials that provide master data for casting optical components (such as lenses), such as molds or male mold master shapes that can be provided through 3D printing, may deteriorate under the influence of the ambient atmosphere. Under the influence of temperature and / or specific humidity levels, this deterioration may involve drying out, thus becoming brittle, deforming, etc. Alternatively or additionally, this deterioration may be due to scratching. Preferably, a method for manufacturing molds for producing optical components is provided that addresses these problems. While this method is particularly suitable for manufacturing optical components, it can also be used for other objects.

[0004] A first aspect provides a method for manufacturing a replica mold for an optical element. The method includes: receiving a dataset providing a three-dimensional representation of an optical element in a three-dimensional printing system; depositing a quantity of master material on a substrate using the three-dimensional printing system to provide a master template according to at least a portion of the dataset; and providing a master template around the master template on the substrate. In the master template, a first quantity of mold material is provided and settled to form a master mold including a master cavity at least partially defined by the master template. The master template is separated from the master mold, and master replication material is cast into the master cavity of the master mold to provide a stable master replica. The master replica is removed from the master mold, and a replica template is provided around the master replica. A second quantity of mold material is provided and settled within the replica template to form a replica mold including a replication cavity at least partially defined by the master replica.

[0005] First, this allows for the optimization of master material for precise deposition, for example, through 3D digital printing. This requirement may not always be compatible with the long shelf life of master objects. Furthermore, this method allows for the optimization of materials used for master replicas to achieve both longevity and precision casting.

[0006] Second, this method allows for the rapid reuse of the substrate. The substrate can be a precision instrument with very precisely defined dimensions and, optionally, precisely defined alignment marks at very precisely defined locations, with tolerances on the order of micrometers or smaller. Such substrates are difficult to manufacture, and the equipment is expensive. Therefore, such substrates are costly. Therefore, it is preferable to reuse the substrate within a short turnaround time to print additional master templates.

[0007] Third, molds may wear down during use. Casting molds from master material can lead to wear on the master material itself, as it may not be optimized for mold casting. Different materials can be chosen for master replicas, and harder materials can be used for casting rather than 3D printing. With appropriate master replicas, numerous molds can be manufactured, providing a virtually unlimited supply of replica molds with replica cavities.

[0008] It should be noted that the method may undergo some variations during implementation depending on the process parameters. With a full understanding of these variations, they can be parameterized or otherwise calculated. These determined calculations can be used to transform the data in the dataset used for manufacturing master parts, ensuring that the components formed by the casting material in the replica mold accurately represent the components characterized by the dataset.

[0009] The first aspect of the implementation further includes applying an alignment module to a substrate before providing a first amount of mold material.

[0010] The alignment module can be used as a marker to provide indication of the master mold part relative to the substrate. This can be used in later stages, for example, for aligning multiple mold parts. In this case, the alignment data provided by the alignment module can be transferred to the replica mold via the master mold replica.

[0011] Another embodiment further includes providing at least one master alignment mark to the master copy by means of at least a portion of the alignment module. This allows alignment data to be transmitted to the copy die for alignment of the copy die to manufacture optical elements.

[0012] Another implementation further includes providing replication mold markings to the replication mold using master alignment marks. Accuracy can be guaranteed by saving and copying alignment data throughout the process.

[0013] In another embodiment, the substrate has a rectangular shape, and the substrate includes holes near each of the four corners, and the alignment module includes a rod disposed in each of the four holes at the corners. This provides a convenient and efficient implementation.

[0014] In another embodiment, removing the master mold part from the master mold includes removing a rod from a hole in the substrate, after which the rod is attached to the master mold. The rod may be retained or removed, depending on compatibility with a particular implementation of the method.

[0015] In another embodiment, the master template includes: a set of walls having an orientation substantially perpendicular to the substrate; and a cover having an orientation substantially parallel to the substrate. The cover can be used to ensure a substantially flat side of the mold opposite the cavity.

[0016] In another embodiment, after the initial amount of mold material has stabilized and the master mold has been removed, the cover is attached to the master mold. The advantage of this embodiment is that the cover provides rigidity. If this is not necessary, for example, because a skeleton-like insert is provided in the mold, or for other reasons, the cover can be removed.

[0017] In another embodiment, the master template has a master template footprint that is larger than the footprint of the substrate, and the method further includes providing a casting base disposed beneath the substrate while providing a first amount of mold material. An advantage of this embodiment is that the master cavity includes a portion defined by the substrate. This, in turn, may be advantageous for alignment purposes.

[0018] In another embodiment, the replication template has a replication template area profile smaller than that of the substrate; and the deposited master material has an object area profile smaller than that of the replication template. In this embodiment, the substrate is not replicated to the replication mold. Second, master templates are printed such that they are fully reproducible and therefore can be replicated onto the replication mold.

[0019] In another embodiment, the copy template occupies an area larger than that of the master copy, defined by alignment marks in the master copy, the holes of which are defined by rods in the master mold. This embodiment allows the holes or other alignment marks to be copied to the master copy, and subsequently to the copy mold.

[0020] Another embodiment further includes surface treatment of the master copy. Surface treatment can be used to improve the properties of the master copy surface, such as smoothness, hardness, or to enhance other physical and / or chemiphysical properties, such as the tendency to adhere to other materials (such as mold materials or alignment element materials).

[0021] In another embodiment, a surface treatment is applied after the master copy is removed from the master mold. Alternatively, a material for reinforcing the master copy may be provided in the master cavity before casting the master copy.

[0022] In another embodiment, the surface treatment includes at least one of milling the master copy and applying a coating to the master copy. In addition to providing a coating, material may also be removed. This can be accomplished by milling or etching. Such milling and etching can be performed across the entire surface or selectively at specific locations.

[0023] Another embodiment further includes providing a master mold skeleton as an example of an insert surrounding the deposited amount of master material before providing the first quantity of mold material. A preferred material for the mold is an elastomer, such as silicone rubber. Typically, such materials and elastomers (but also other materials) may not provide sufficient rigidity to fit the mold for casting with the desired tolerances. This embodiment addresses this problem.

[0024] In another embodiment, the master mold skeleton comprises at least one of an organic polymer and a metal. Such materials allow for the relatively inexpensive and simple manufacture of inserts.

[0025] In another embodiment, the first and second mold quantities comprise an elastomer, such as silicone rubber. Such materials allow for relatively easy casting and can be suitably adapted to the shape of other materials. Secondly, any casting can be easily removed.

[0026] In another embodiment, the master copy material includes polyurethane. Polyurethane may stabilize rapidly after casting (curing, hardening, solidifying), depending on the detailed composition used. Secondly, it comes in a wide variety, including transparent varieties. Transparent varieties may be useful for optical inspection of the master copy.

[0027] A second aspect provides a method for manufacturing an optical element. The method includes manufacturing a first production mold component according to any one of the preceding claims, wherein the amount of deposited master material conforms to a first subset of a dataset; and manufacturing a second production mold component according to any one of the preceding claims, wherein the amount of deposited master material conforms to a second subset of the dataset, the second subset being complementary to the first subset. The method further includes combining the first and second production molds such that the cavities of the first and second production molds face each other to form a product cavity, providing product material in the product cavity, the product cavity having a shape equivalent to that of the optical element; stabilizing the product material to form the optical element; and removing the first and second production mold components from the optical element. Attached Figure Description

[0028] The various aspects and their implementation will now be discussed in more detail with reference to the accompanying drawings. In the drawings,

[0029] Figure 1 The flowchart is shown.

[0030] Figure 2 This shows two master templates on the substrate;

[0031] Figure 3 A substrate with a template is shown.

[0032] Figure 4 The master mold is shown;

[0033] Figure 5 This shows a copy of the master copy, which serves as a copy of the master copy.

[0034] Figure 6 This shows a master copy with a template.

[0035] Figure 7 This illustrates a replication mold based on a master copy.

[0036] Figure 8 The combined replica mold is shown; and

[0037] Figure 9 : This shows the optical element. Detailed Implementation

[0038] Combining Figure 1 The flowchart 100 shown and the diagram illustrate Figures 2 to 9 The accompanying drawings of the product for each part of the flowchart 100 are used to discuss various aspects and their implementations. A brief overview of each part of the flowchart 100 is provided in the list below.

[0039] 102 Start Process

[0040] 104 Print Master

[0041] 106 Apply skeleton

[0042] 108 application rod

[0043] 110 Apply template

[0044] 112 provides mold material

[0045] 114 Apply cover

[0046] 116 stable

[0047] 118 retrieve template

[0048] 120 Remove the printed substrate

[0049] 122 Casting Master Copy

[0050] 124 stable

[0051] 126. Retrieve the master copy.

[0052] 128 Apply skeleton

[0053] 130 application rod

[0054] 132 Apply template

[0055] 134 provides mold material

[0056] 136 Apply cover

[0057] 138 stable

[0058] 140 Remove the master copy from the mold

[0059] 142. Have all the working molds been completed?

[0060] 144 Apply rods in mold

[0061] 146 combination mold

[0062] 148 Supply Product Materials

[0063] 150 stable

[0064] 152 Remove the product from the mold

[0065] End of 154

[0066] The process begins at start-stop 102 and continues by receiving data through a 3D printer, which is configured to deposit fluid material onto substrate 202. Figure 2 An isometric view and cross-section of substrate 202 are shown. In step 104, a first amount of master material is deposited on substrates 202 and 200 to form a first master template 204 and a second amount of master material to form a second master template 206.

[0067] The first master template 204 and the second master template 206 can provide a representation of the front and rear sides of a prescription lens. In another example, the first master template 204 and the second master template 206 provide the rear or front side of a left and right prescription lens. Although Figure 2 Two amounts of master material deposited on substrate 202 are shown, but it should be noted that only one amount of master material deposited on substrate 202 can also be used in various aspects and examples thereof.

[0068] A master material is deposited using a 3D printing process. Preferably, a UV-curable material is used as the master material. Figure 2 In the configuration shown, two master templates are printed on substrate 202. In another example, one or more master templates are provided on substrate 202.

[0069] In the context of this application, the 3D printing process is a process of depositing fluid in a small, controlled amount using a dispensing head. The movement of the dispensing head can be controlled based on data received from the printing process. This allows the 3D printer to precisely deposit small amounts of fluid at specific locations on a substrate and on top of the already deposited fluid. After deposition, the master material is allowed to stabilize, for example, by curing under the influence of one or more of UV radiation and thermal energy. In another example, the master fluid cures while losing thermal energy.

[0070] After depositing the master material, a mold skeleton 214 is provided around the first master mold part 204 and the second master mold part 206, such as Figure 3 The right side portion is shown. The mold skeleton 214 includes an open structure that can be configured as a cage surrounding the first master mold 204 and the second master mold 206. The mold skeleton 214 is open to fluids that can be used to form the mold, as will be discussed below. The mold skeleton 214 can enhance the rigidity of the mold to be formed. For this purpose, the mold skeleton 214 may include organic polymers such as PETG (polyethylene terephthalate), PE (polyethylene), or other combinations of two or more of these. In another embodiment, the mold skeleton 214 may include one or more metals such as iron, chromium, vanadium, magnesium, copper, or other combinations of two or more of these. In another embodiment, the mold skeleton 214 includes one or more metals and one or more organic polymer materials.

[0071] In this example, the mold skeleton 214 is provided as an example of an insert for a mold, which will be discussed below. In another embodiment, the skeleton 214 may be provided as an external skeleton, which may be provided at least partially outside the mold, which will be discussed below.

[0072] In substrate 202, substrate holes 208 are provided. Figure 2 In this example, holes are provided at each corner of the rectangular substrate 202. Additionally, additional holes are provided near the center of the long side of the rectangular substrate; there is one hole on each side of the center of each long side. In step 108, a rod 212 or pin is disposed in the substrate hole 208. The rod 212 comprises steel, a single metallic component (such as aluminum or iron), or another metallic composition. In another embodiment, the rod 212 comprises an organic polymer. In step 110, a master template 210 or casting box is provided around the mold skeleton 214. In this embodiment, the area occupied by the master template 210 is larger than the area occupied by the substrate 202. This means that the master template 210 surrounds the substrate 202. Below the substrate, a casting base plate 218 is provided. The casting base plate 218 serves as the bottom of the casting box provided by the master template 210 and the casting base plate 218.

[0073] Subsequently, in step 112, a mold material is provided in the casting box thus provided. While the mold material is being cast in the casting box, a cover 216 can be placed on top of the casting box. Therefore, the cover 216 can be considered part of the mold. The cover 216 can be supported by a rod 212. In another embodiment, the mold material is supplied to the casting box while the cover 216 is already placed on top of the casting box. After casting, the mold material is allowed to stabilize. An elastomer such as silicone rubber is preferably used as the mold material. However, another elastomer or another material can also be used—as long as it is a material to which the master material is resistant once the master material has stabilized.

[0074] Figure 4 The diagram illustrates a master mold 220 provided after the master template 210 has been removed in step 118 and the substrate 202 having the first master mold element 204 and the second master mold element 206 has been removed from the first master mold cavity 222 and the second cavity 224, respectively. Figure 4 In the example shown, rod 212 and cover 216 are attached to master mold 220, for example, by means of the adhesive properties of the material of master mold 220. This means that when substrate 202 is separated from mold 220, rod 212 is removed from substrate. In another embodiment, at least one of cover 216 and rod 212 is not attached to master mold 220 and can be removed from master mold 220. Optionally, other alignment elements may be provided at a later stage.

[0075] In step 122, the master replication material is cast into the first master cavity 222, the second cavity 224, and the remaining cavities formed in the master mold 220 after removing the substrate 202. Transparent polyurethane can be used as the master replication material. This allows for convenient casting and relatively rapid curing of the material into a solid structure, which is as follows: Figure 5 The master copy shown is 230.

[0076] Figure 5 The master copy 230 is shown after being removed from the master mold in step 126. The master copy 230 is provided with a master copy hole 232, as defined by the rod 212 in the master mold 220. The master copy 230 includes a first copy member 234 and a second copy member 236, which serve as copies of the first master member 204 and the second master member 206, respectively.

[0077] The master copy 230 can then undergo surface treatment. Such surface treatment may include applying a coating. This coating may provide scratch protection for the master copy 230. Alternatively or additionally, this coating may enhance the smoothness of the surface of the master copy 230. Alternatively or additionally, the coating may enhance other or more properties of the master copy 230. Alternatively or additionally, the master copy 230 may be corona-treated, for example, by means of a flame.

[0078] Master copy 230 serves as a master for providing a working mold. In step 128, an equivalent to [missing information] can be provided on master copy 230. Figure 3 The mold skeleton structure of the skeleton shown. Figure 6 A master copy 230 is shown, in which a copy rod 242 disposed in a master copy hole 232 is provided in step 130. In step 132, a copy template 244 is provided on the master copy 230. In this example, the copy template 244 includes a barrier between a first copy member 234 and a second copy member 236.

[0079] In this example, the copy template 244 has a smaller area than the master copy 230 and a larger area than the first copy 234 and the second copy 236. More specifically, the area occupied by each of the two spaces provided by the copy template 244 is larger than the area defined by the four master copy holes 232 in each space of the copy template 244.

[0080] By providing a barrier, a first working mold 252 can be provided based on a first replica 234, and a second working mold 254 can be provided based on a second replica 236, such as... Figure 7 As shown. In step 134, a first working mold 252 and a second working mold 254 are provided by casting molding material into the space provided by the replication template 244 and the working replica 230. The first working mold 252 has a first working cavity 256 complementary to the first master mold 204. The second working mold 254 has a second working cavity 258 complementary to the second master mold 206.

[0081] Optionally, the cap can be applied to the top of the copy template 234, equivalent to combining Figure 3 Step 114 is described. Subsequently, as described above, the molding compound is stabilized. In step 140, the master copy is removed from the first working mold 252 and the second working mold 254.

[0082] If all the production mold parts for manufacturing a particular optical element have been manufactured, the method continues to step 144. If it is determined in step 142 that more mold parts are needed to manufacture the optical element, the method branch returns to step 104. In the example discussed here, the two complementary working molds are manufactured in parallel. In another example, the complementary molds are manufactured serially.

[0083] Optionally, the copying rod 242 is also removed from the first working mold 252 and the second working mold 254. If this is the case, in step 146, the mating mold rod 262 is positioned in the holes of the first working mold 252 and the second working mold 254. The holes in the first working mold 252 and the second working mold 254 are formed by means of the copying rod 242. When the mold components are assembled in step 146, the mating rod 262 allows the first working mold 252 and the second working mold 254 to be precisely aligned, such as... Figure 8 As shown. In step 148, the product material is cast into the cavity 270 provided by the first working mold 252 and the second working mold 254 for manufacturing the optical element 290, as shown. Figure 9 As shown. The product material is preferably a transparent resin.

[0084] Therefore, various examples relate to a method for manufacturing a mold used to manufacture optical elements. A master template for the optical element is manufactured on a substrate using precision material deposition techniques, such as 3D printing. Next, a master template mold component is manufactured by casting mold material onto the deposited master template. The master template mold component is used to manufacture a master template replica by casting a master template replication material into a cavity of the master template mold. The master template replication material may differ from the master template material. Next, a replica mold component is manufactured by casting mold material onto the master template replica. The replica mold component is preferably part of a larger mold having two or more components and is used to manufacture the optical element by combining the mold components to provide a cavity for casting the optical element.

Claims

1. A method of manufacturing a replication mold for an optical element, the method comprising: receiving, in a three-dimensional printing system, a data set providing a three- dimensional representation of the optical element; depositing, by the three-dimensional printing system, an amount of master material on a substrate to provide at least a portion of a master form according to at least a portion of the data set; providing a master template on the substrate around the master form; providing a first amount of mold material in the master template; allowing the first amount of mold material to stabilize, thereby forming a master mold comprising a master cavity at least partially defined by the master form; separating the master form from the master mold; casting a master replication material in the master cavity of the master mold to provide a master replication; allowing the master replication material to stabilize; removing the master replication from the master mold; providing a replication template around the master replication; providing a second amount of mold material in the replication template; allowing the second amount of mold material to stabilize, thereby forming a replication mold comprising a replication cavity at least partially defined by the master replication.

2. The method of claim 1, further comprising, prior to providing a first amount of mold material, applying an alignment module to the substrate.

3. The method of claim 2, further comprising providing at least one master alignment mark to the master replication by means of at least a portion of the alignment module.

4. The method of claim 3, further comprising providing a replication mold mark to the replication mold by means of the master alignment mark.

5. The method of any one of claims 2 to 4, wherein the substrate has a rectangular shape and the substrate comprises a hole near each of four corners, and applying the alignment module comprises disposing a rod in each of the four holes at the corners.

6. The method of claim 5, wherein removing the master form from the master mold comprises removing the rod from the hole in the substrate, the rod being connected to the master mold after removing the rod from the substrate.

7. The method of any one of the preceding claims, the master template comprising: a set of walls having an orientation substantially perpendicular to the substrate; and a lid having an orientation substantially parallel to the substrate.

8. The method of claim 7, wherein the lid is connected to the master mold after the first amount of mold material has stabilized and the master template is removed.

9. The method of any one of the preceding claims, wherein the master template has a master template footprint larger than a substrate footprint of the substrate, and the method further comprises providing a casting base disposed under the substrate at the same time as providing the first amount of mold material.

10. The method of any one of the preceding claims, wherein the replication template has a replication template footprint smaller than a substrate footprint profile of the substrate; and the replication template has a replication template footprint profile smaller than a substrate footprint profile of the substrate. The amount of master material deposited has an object footprint that is smaller than the footprint of the replication template.

11. The method of claim 10, when dependent on the scope of claim 3, wherein the replication template footprint is larger than the area of the master replica defined by a hole in the master replica, the hole being defined by the stem in the master mold.

12. The method of any one of the preceding claims, further comprising surface treating the master replica.

13. The method of claim 12, wherein the surface treatment is applied after the master replica is removed from the master mold.

14. The method of any one of claims 12 and 13, wherein the surface treatment comprises at least one of milling the master replica and applying a coating to the master replica.

15. The method of any one of the preceding claims, further comprising providing a master mold skeleton around the amount of master material deposited prior to providing the first amount of mold material.

16. The method of claim 15, wherein the master mold skeleton comprises at least one of an organic polymer and a metal.

17. The method of any one of the preceding claims, wherein the first amount of mold material and the second amount of mold material comprise an elastomer, such as silicone rubber.

18. The method of any one of the preceding claims, wherein the master replication material comprises polyurethane.

19. A method for manufacturing an optical element, the method comprising: manufacturing a first production mold part according to the method of any one of the preceding claims, wherein the amount of master material deposited complies with a first subset of the data set, the first production mold comprising a first cavity; providing a product material in the first cavity; stabilizing the product material, thereby forming the optical element; and removing the first production mold part from the optical element.

20. The method of claim 19, further comprising: manufacturing a second production mold part according to the method of any one of the preceding claims, wherein the amount of master material deposited complies with a second subset of the data set, the second subset being complementary to the first subset; combining the first production mold with the second production mold such that the cavities of the first production mold and the second production mold face each other, thereby forming a product cavity; and providing a product material in the product cavity, the product cavity having a shape that is identical to the shape of the optical element.

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