Micro-Optic Grid Support Structure for 3D Laser Writing
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Solution Overview
Problem
Existing methods for manufacturing micro-optics using 3D laser writing are time-consuming due to the complexity of retaining structures, which require significant time to create and often necessitate additional openings for excess photoresist removal.
Innovation Solution
A method involving the creation of a grid structure around optical components using 3D laser writing, followed by filling this grid structure with a curable polymer and curing it to form a support structure, which simplifies the design and reduces production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solid retaining structures are used to surround optical elements, then the optical elements are firmly positioned at defined distances and orientations, but the manufacturing time increases considerably
Solution Approach 1:
The retaining structure is segmented into a grid structure with multiple struts arranged in orthogonal directions, rather than using a solid continuous structure. This segmentation reduces the amount of material that needs to be cured while maintaining positioning precision through the distributed strut network.
Solution Approach 2:
The grid structure provides localized support at specific positions around the optical element, with struts positioned only where needed for stabilization. This local quality approach concentrates support where required rather than using uniform solid material throughout the entire retaining volume.
2Reliability
If solid retaining structures are created by 3D laser writing, then the optical elements are surrounded and positioned correctly, but the creation process takes a considerable amount of time
Solution Approach 1:
The retaining structure is divided into discrete grid struts that can be cured independently and in parallel, reducing the total curing time compared to a solid structure that would require curing the entire volume sequentially.
Solution Approach 2:
The grid structure provides sufficient support with less material than a solid structure would require. The struts are positioned to provide just enough support for stability without the excess material that would increase curing time.
3Ease of manufacture
If openings are provided in the retaining structure for photoresist removal, then excess photoresist can flow out, but the design becomes complex and requires adaptation for different micro-optics
Solution Approach 1:
The grid structure inherently creates gaps and channels between the struts that serve as photoresist removal pathways, eliminating the need for dedicated openings. The segmented strut design naturally provides fluid flow paths without requiring additional structural features.
Solution Approach 2:
The grid struts serve multiple functions: providing mechanical support for positioning and simultaneously creating channels for photoresist removal. This multi-functionality eliminates the need for separate opening features and reduces design complexity.
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 allows for the rapid creation of a simpler support structure that surrounds optical components, reducing production time and eliminating the need for additional openings, thereby enhancing manufacturing efficiency.
Implementation Method 1
3D laser writing takes place in the liquid phase, wherein a photoresist is cured at the location of the voxel, in particular by means of 2-photon polymerization
Implementation Method 2
filling the grid structure with a curable polymer
Data Source
AI summary
A method for manufacturing a micro-optics, including the steps of creating at least one optical component, creating a grid structure of a support structure at least partially surrounding the at least one optical component, filling the grid structure with a curable polymer, and curing the polymer in the grid structure to create the support structure.