Custom Optical Lens Prototyping with Adjustable Membrane Molding
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Solution Overview
Problem
Existing methods for manufacturing optical components, particularly lenses, face challenges in achieving efficient and fast production while maintaining high optical quality, with traditional molds being slow, grinding/3D milling being costly and time-consuming, and rapid prototyping via 3D printing often resulting in low quality.
Innovation Solution
A method involving the use of a cavity to shape and cure a liquid material into a rigid optical component, utilizing adjustable solid state structures and controlled viscosity, with UV radiation and pressure adjustments to form precise optical surfaces, followed by molding or direct formation of the optical component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional molds are used for manufacturing optical components, then manufacturing precision can be maintained, but production time and lead time increase significantly
Solution Approach 1:
The patent changes the physical state parameter of the optical material from solid (traditional molding) to liquid (curable liquid material), enabling the material to flow and conform to the mold cavity quickly, then transforms it back to solid state through curing. This parameter change allows rapid production while maintaining precise optical surfaces defined by the mold geometry.
2Manufacturing precision
If grinding or 3D milling is used to shape optical components, then precise optical surfaces can be achieved, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent replaces mechanical removal processes (grinding, milling) with a chemical/physical transformation process. Instead of mechanically removing material to achieve the desired shape, the liquid material is poured into a mold cavity and cured in place, forming the precise optical surface through the mold geometry rather than through mechanical subtraction.
3Productivity
If 3D printing is used for rapid prototyping of optical components, then production speed increases, but optical quality deteriorates
Solution Approach 1:
The patent introduces a mold cavity as an intermediary that defines the precise optical geometry. Instead of relying on the 3D printing process itself to create the optical surface (which limits precision), the liquid material is formed against the precisely defined mold cavity walls, transferring the mold's geometric precision to the optical component while maintaining rapid production.
4Adaptability or versatility
If liquid material is used instead of solid material for molding, then production time decreases and adaptability increases, but control over material properties becomes more difficult
Solution Approach 1:
The patent utilizes the phase transition of the optical material from liquid to solid state through curing. In the liquid state, the material is highly adaptable and can flow to conform to any mold cavity shape. Upon curing, it transitions to a solid state with fixed properties, enabling precise control over the final optical component's characteristics while maintaining production flexibility.
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
Enables fast and cost-effective manufacturing of optical components with high optical quality by shaping and curing liquid material into rigid form, allowing for precise control over surface shapes and properties.
Implementation Method 1
d1) curing the liquid material (4) filled into the at least one cavity (2) so that the liquid material (4) becomes a rigid material (40)
Data Source
AI summary
The present invention relates to a method for producing at least one optical component (1), comprising the steps of: a) Providing at least one cavity (2), wherein the at least one cavity (2) is delimited on a first side by a surface (3a) of a first membrane portion (3), wherein a shape of the first membrane portion (3) is adjustable; b) Filling a material (4) into the at least one cavity (2) for forming at least one optical component (1), such that the material (4) contacts a surface (3a) of the first membrane portion (3); c) Adjusting the shape of the first membrane portion (3); d) Curing the material (4) filled into the at least one cavity (2) so that the material (4) forms a first interface (e.g. a first optical surface) (1a) of the at least one optical component (1), which first interface (1a) comprises a shape defined by a shape of the surface (3a) of the first membrane portion (3).