3D Printed Hybrid Polymer Optical Element with Integrated Functions
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Solution Overview
Problem
Existing optical systems are complex, heavy, and costly due to the need for multiple precisely aligned components, which are often made from spherical surfaces that require expensive manufacturing processes. Additionally, 3D printed polymer optics suffer from layer boundaries, surface roughness, and reduced transmission, limiting their optical quality and functionality.
Innovation Solution
A procedure for digital production of optical elements using 3D printing with inorganic-organic hybrid polymer materials, which allows for the generation of complex three-dimensional structures with integrated functionalities such as light-breaking, absorbing, reflecting, and scattering elements, achieved through surface and volume modifications using laser radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical systems use multiple precisely aligned components with spherical surfaces, then excellent imaging properties are achieved, but the system becomes heavy, bulky, and costly
Solution Approach 1:
The patent combines multiple optical functions (refraction, reflection, absorption, aperture control) into a single 3D-printed optical element with freeform surfaces, eliminating the need for multiple separate components and their precise alignment, thereby reducing system weight and complexity while maintaining imaging performance
Solution Approach 2:
The single optical element performs multiple functions simultaneously: it acts as a refractive lens, includes integrated aperture stops, incorporates reflective surfaces, and contains light-absorbing regions, replacing what traditionally required several separate optomechanical components
2Manufacturing precision
If conventional optical systems use multiple components with anti-reflective coatings, then optical performance is improved, but the complexity and cost increase and light throughput decreases
Solution Approach 1:
The patent integrates anti-reflective functionality directly into the 3D-printed optical element through freeform surface design and material properties, eliminating the need for separate anti-reflective coating processes and reducing overall system complexity
Solution Approach 2:
The optical element's freeform surfaces provide both imaging functionality and anti-reflective properties in a single component, reducing the number of processing steps and simplifying the overall optical system design
3Ease of manufacture
If 3D printing is used to manufacture polymer optics, then component complexity is reduced and manufacturing is simplified, but layer boundaries and surface roughness reduce transmission and optical quality
Solution Approach 1:
The patent uses inorganic-organic hybrid polymers with specific refractive indices and optical properties that minimize layer boundary effects and improve transmission, along with optimized 3D printing parameters to reduce surface roughness while maintaining freeform surface capabilities
Solution Approach 2:
The patent employs inorganic-organic hybrid polymer composites that combine the ease of 3D printing with improved optical properties, including reduced layer boundary visibility and better transmission characteristics compared to conventional organic polymers
4Device complexity
If freeform surfaces are used to reduce component complexity, then fewer components are needed, but expensive tooling and complex post-processing are required
Solution Approach 1:
The patent replaces expensive mechanical machining processes (diamond turning, precision pressing) with 3D printing technology that inherently generates freeform surfaces without requiring complex tooling or post-processing steps
Solution Approach 2:
The patent uses 3D printing parameters and material formulations that enable direct fabrication of freeform surfaces with adequate surface quality, eliminating the need for expensive post-processing operations required by conventional manufacturing methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the complexity and weight of optical systems, improves optical quality by minimizing layer boundaries and surface roughness, and enables the integration of multiple functionalities, resulting in higher transmission and reliability compared to traditional methods.
Implementation Method 1
The printing material contains an inorganic-organic hybrid polymer... a three-dimensional structure is produced from a printing material containing an inorganic-organic hybrid polymer by means of 3D printing
Implementation Method 2
at least one region with an additional functionality is produced in the three-dimensional structure by means of a region-by-region modification on the surface and/or in the volume of the structure
Implementation Method 3
The interaction within the volume occurs through nonlinear absorption processes of ultrashort laser pulses, which in turn cause microscopic material modification of the printing material. The geometrical form of this modification can be manipulated through the focusing optics and the laser parameters used
Implementation Method 4
a three-dimensional structure is produced from a printing material containing an inorganic-organic hybrid polymer... the additional functionality is selected from the group consisting of light-refracting elements
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for digitally producing an optical element having integrated functionalities, wherein a three-dimensional structure is produced from a printing material containing an inorganic-organic hybrid polymer by means of 3D printing, and a modification in regions on the surface and/or in the volume of the structure produces at least one region having an additional functionality. The invention also relates to an optical element containing a three-dimensional structure produced by means of 3D printing from an inorganic-organic hybrid polymer, wherein the structure has, on the surface and/or in the volume, at least one region having an additional functionality.