3D-Printed Optical Lens Layering for Uniform Surface Smoothing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing of optical lenses results in poor surface quality due to asperities formed by layer edges, and existing methods to improve this quality either increase manufacturing time or are inefficient.
Innovation Solution
The method involves varying the thickness and exposed length of layers based on their position in the optical element, with thicker layers near the periphery and thinner layers near the apex, to facilitate uniform smoothing and reduce manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thickness of layers is decreased to minimize asperities and improve surface quality, then surface quality is improved, but manufacturing time increases since more layers have to be deposited
Solution Approach 1:
The patent applies local quality by varying the layer thickness according to the radial position in the optical lens. Layers at the periphery have greater thickness than layers near the apex, creating non-uniform layer distribution that optimizes both surface quality and manufacturing efficiency for different regions of the lens
Solution Approach 2:
The patent changes the parameter of layer thickness from a constant value to a position-dependent value. The thickness parameter is modified based on radial distance from the apex, allowing the system to achieve uniform asperity heights across different regions while maintaining reasonable manufacturing time
2Manufacturing precision
If post-processing polishing is applied to improve surface quality, then surface quality is improved, but manufacturing time increases
Solution Approach 1:
The patent performs preliminary action by pre-configuring the layer thickness distribution during the additive manufacturing process itself. By anticipating the need for uniform asperity heights, the system deposits layers with varying thicknesses that naturally compensate for positional differences, reducing the burden on subsequent polishing operations
Solution Approach 2:
The patent applies preliminary anti-action by depositing thicker layers at the periphery where asperities would naturally be more pronounced. This pre-compensation counteracts the expected excessive asperity formation in peripheral regions, creating a more uniform surface that requires less corrective polishing
3Ease of manufacture
If uniform layer thickness is used throughout the optical element, then manufacturing process is simplified, but smoothing time increases due to non-uniform asperity heights
Solution Approach 1:
The patent transitions from uniform layer thickness to position-dependent layer thickness. By making the layer quality (thickness) vary locally based on radial position, the system achieves uniform asperity heights across the entire optical element, significantly reducing the time required for smoothing operations
Solution Approach 2:
The patent performs preliminary action by pre-calculating and pre-depositing layers with position-specific thicknesses. This anticipates the smoothing requirements and prepares the intermediate optical element in advance, so that the subsequent smoothing operation can proceed uniformly and efficiently across all regions
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 production of optical lenses with improved surface quality without increasing manufacturing time, by ensuring uniform smoothing of asperities across the lens surface.
Implementation Method 1
The additive manufacturing process needs to be precisely performed; in particular a new layer needs to be positioned very accurately on the already polymerised layer to correctly manufacture the optical lens
Implementation Method 2
a second method consists in post-processing the surface of the lens by polishing the asperities
Data Source
AI summary
A method for manufacturing an optical lens by additive manufacturing, includes steps of: depositing a first layer having a first thickness; —depositing a second layer, having a second thickness, onto the first layer, the second layer forming a first asperity with the first layer; depositing a third layer having a third thickness; depositing a fourth layer having a fourth thickness onto the third layer, thereby forming an intermediate optical element, the fourth layer forming a second asperity with the third layer; and smoothing the first asperity and the second asperity on the intermediate optical element, thereby forming the optical lens. The second thickness and the fourth thickness are different. A corresponding intermediate optical element is also described.