Electroforming Mold for Optical Lens Replication
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Solution Overview
Problem
Producing complex optical lens surfaces is time-consuming and costly, especially when using machining or additive manufacturing methods, and it is difficult to efficiently replicate these surfaces for mass production of optical lenses.
Innovation Solution
A method involving a monolithic optical lens element with a finished surface, coated with an electrically conductive material, followed by depositing a metal layer to replicate the surface, allowing for the separation of the lens element and the metal element to form a mold that replicates the optical surface, which can then be used to produce multiple optical lenses with the same surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining methods are used to produce complex optical lens surfaces, then manufacturing precision can be achieved, but the production time and cost increase significantly
Solution Approach 1:
The patent applies the copying principle by creating a master optical lens with the desired complex surface, then using it as a template to produce multiple replicas through electroforming. The metal layer is deposited to replicate the master surface geometry, and after separation, the metal replica serves as a mold for mass production. This eliminates the need to machine each lens individually, dramatically reducing production time while maintaining precision through the replication process.
2Productivity
If additive manufacturing is used to produce complex optical lens surfaces, then production speed improves, but manufacturing precision and surface quality deteriorate
Solution Approach 1:
Instead of adding material layer by layer (which limits precision), the patent uses a precision-machined master lens as a template and replicates its surface through electroforming. The metal deposition process captures the master surface geometry with high fidelity, producing replicas with optical-grade precision while enabling batch production through the reusable mold approach.
3Manufacturing precision
If machining methods are used to manufacture mold surfaces, then manufacturing precision can be achieved, but the cost and complexity of the process increase
Solution Approach 1:
The patent inverts the traditional approach by using a precision optical lens as the template to create the mold, rather than machining the mold surface directly. The electroforming process replicates the lens surface geometry onto a metal mold, transferring the precision requirement from the mold-making process to the master lens, which can be independently optimized. This significantly reduces mold manufacturing cost and complexity.
4Productivity
If traditional molding methods are used, then mass production capability is achieved, but the initial mold manufacturing is expensive and time-consuming
Solution Approach 1:
The patent performs the precision surface creation in advance by manufacturing a master optical lens with the desired complex surface geometry. This master lens then serves as a reusable template for creating multiple metal molds through electroforming. The preliminary creation of the master lens consolidates the precision work into a single operation, allowing subsequent mold production to proceed more quickly and at lower cost.
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 method efficiently and cost-effectively replicates complex optical surfaces, enabling the mass production of optical lenses with precise optical properties, such as progressive or multifocal surfaces, while reducing the need for expensive machining processes.
Implementation Method 1
depositing on the coated finished optical surface a layer of metal to produce a metal element having a surface which is a replication of the finished optical surface
Data Source
AI summary
Disclosed is a method for producing a mold obtained by providing a monolithic optical lens element having at least a finished optical surface, the monolithic optical lens element being made of an organic material. The method includes: coating the finished optical surface with an electrically conductive material; depositing on the coated finished optical surface a layer of metal to produce a metal element having a surface which is a replication of the finished optical surface; and separating the monolithic optical lens element and the metal element, the metal element forming a mold replicating the finished optical surface of the monolithic optical lens element.