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Optical Engineering

Nonisothermal glass molding for the cost-efficient production of precision freeform optics
Author(s): Anh-Tuan Vu; Holger Kreilkamp; Olaf Dambon; Fritz Klocke
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Paper Abstract

Glass molding has become a key replication-based technology to satisfy intensively growing demands of complex precision optics in the today’s photonic market. However, the state-of-the-art replicative technologies are still limited, mainly due to their insufficiency to meet the requirements of mass production. This paper introduces a newly developed nonisothermal glass molding in which a complex-shaped optic is produced in a very short process cycle. The innovative molding technology promises a cost-efficient production because of increased mold lifetime, less energy consumption, and high throughput from a fast process chain. At the early stage of the process development, the research focuses on an integration of finite element simulation into the process chain to reduce time and labor-intensive cost. By virtue of numerical modeling, defects including chill ripples and glass sticking in the nonisothermal molding process can be predicted and the consequent effects are avoided. In addition, the influences of process parameters and glass preforms on the surface quality, form accuracy, and residual stress are discussed. A series of experiments was carried out to validate the simulation results. The successful modeling, therefore, provides a systematic strategy for glass preform design, mold compensation, and optimization of the process parameters. In conclusion, the integration of simulation into the entire nonisothermal glass molding process chain will significantly increase the manufacturing efficiency as well as reduce the time-to-market for the mass production of complex precision yet low-cost glass optics.

Paper Details

Date Published: 5 May 2016
PDF: 13 pages
Opt. Eng. 55(7) 071207 doi: 10.1117/1.OE.55.7.071207
Published in: Optical Engineering Volume 55, Issue 7
Show Author Affiliations
Anh-Tuan Vu, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)
Holger Kreilkamp, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)
Olaf Dambon, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)
Fritz Klocke, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)

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