Optical Element Mould Fabrication Using 3D-Printed Master Pieces
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Solution Overview
Problem
Milling processes for manufacturing optical element moulds result in scratches due to sharp cutters, leading to light scattering issues, which are undesirable in precision optical applications.
Innovation Solution
A method involving three-dimensional printing of master pieces with smooth surfaces, followed by deposition of mould substance in formworks to create scratch-free moulds, using alignment elements for precise alignment and reinforcement structures for flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If milling processes are used to manufacture moulds, then manufacturing capability is provided, but scratches are created on the cavity surface leading to light scattering
Solution Approach 1:
The patent replaces the mechanical milling process with a three-dimensional printing process. Instead of using rotating cutters that mechanically remove material and create scratches, the system deposits material layer by layer to build the mould cavity. This substitution of mechanical removal with additive deposition eliminates the source of surface scratches while maintaining manufacturing capability.
Solution Approach 2:
The patent changes the fundamental manufacturing parameters from mechanical cutting parameters (cutter speed, feed rate, depth of cut) to deposition parameters (layer thickness, deposition speed, material viscosity). This parameter transformation enables the creation of smooth surfaces without mechanical contact, resolving the contradiction between manufacturability and surface quality.
2Manufacturing precision
If three-dimensional printing is used to create master pieces, then scratch-free surfaces are achieved, but additional process steps are required
Solution Approach 1:
The patent segments the mould manufacturing process into distinct functional stages: first creating master pieces with the desired optical surfaces using 3D printing, then using these masters to form mould cavities through deposition. This segmentation allows each stage to be optimized independently - the master piece creation achieves surface smoothness while the subsequent mould formation handles the complexity of cavity creation and assembly.
Solution Approach 2:
The master piece acts as an intermediary element between the digital design and the final mould cavity. Instead of directly printing the complex mould cavity which would require precise tooling paths, the system first creates a simpler master piece that defines the optical surface, then uses this master to form the mould cavity through material deposition. This intermediary approach reduces overall process complexity while maintaining surface quality.
Data Source
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AI summary
One or more master pieces, representing, in conjunction, an optical element like a lens, are printed on a substrate, for example by deposition of droplets of a master substance. In case of one or more master pieces, the pieces are well aligned relative to one another. The master substance is allowed to settle and subsequently, a mould substance is provided in one or more formworks provided around the master pieces. The mould substance is allowed to settle, thus providing one or more mould pieces with a partial cavity being the negative of the one or more master pieces. By proper alignment of the mould pieces, the partial cavities form a single compound cavity in which a lens compound may be provided for manufacturing of the optical element.