Scratch-Free Optical Moulds from 3D-Printed Master Pieces
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Solution Overview
Problem
Milling processes for manufacturing moulds for optical elements result in scratches that cause light scattering, which is 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 moulds without mechanical processing, using alignment elements and reinforcement structures for precise alignment and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If milling processes are used to manufacture moulds for optical elements, then the moulds can be manufactured with conventional machining methods, but scratches are created on the cavity surface that cause light scattering
Solution Approach 1:
The patent replaces mechanical milling processes with three-dimensional printing technology to manufacture moulds for optical elements. This substitution eliminates mechanical contact that causes scratches on the cavity surface, thereby preventing light scattering while maintaining manufacturability through additive manufacturing processes.
Solution Approach 2:
The patent uses three-dimensional printing to create precise digital copies of the optical element design directly into the mould cavity. This copying process from digital model to physical mould eliminates the need for mechanical machining, producing scratch-free surfaces that prevent light scattering while accurately replicating the optical element geometry.
2Object-affected harmful factors
If three-dimensional printing is used to manufacture master pieces, then smooth scratch-free surfaces are achieved, but new manufacturing processes and equipment are required
Solution Approach 1:
The patent replaces complex mechanical machining systems with three-dimensional printing technology. While this introduces new manufacturing equipment, it eliminates the need for multiple machining operations, tool changes, and post-processing steps, ultimately simplifying the overall manufacturing system while producing superior scratch-free surfaces.
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
The method produces scratch-free or low-defect moulds that reduce light scattering, enabling high-quality optical element production.
Implementation Method 1
depositing on a first substrate area, by the three-dimensional printing system, a first amount of master substance in accordance with the first dataset to provide a first master piece
Implementation Method 2
The mould substance may settle by virtue of two materials in the mould substance to react, by reaction of the mould substance with matter in the environment of the mould substance, like, oxygen, nitrogen, another gas, water vapour or atomised water or other liquid
Implementation Method 3
the mould substance may be allowed to settle by virtue of evaporation of a solvent, under influence of temperature, UV curing or any other process of adding energy to or withdrawing energy from the mould substance
Data Source
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.