Accumold

Paul Runyan, VP Sales & Marketing, Accumold Micro-optics encompasses components like tiny lenses, beam-splitters, prisms, light-pipes, and other optical parts ranging from 20 microns to 1 mm in size, or larger optical components with micron-level features. These components drive the miniaturization trend in various light-involved applications, significantly cutting manufacturing costs. They are integral in numerous applications, such as sensors, medical diagnostics, DataCom applications, fitness and medical diagnostic wearables, and emerging technologies like augmented reality glasses and contact lenses. Precision in Micro Molding for Micro-Optics The fabrication of micro-optic components demands an exceptional level of precision, which only the most experienced and specialized micro molding companies can provide. Achieving the exacting tolerances required for these delicate micro-optic parts necessitates a deep and specialized processing knowledge that is distinctly different from that used for typical mechanical parts. This advanced level of expertise is essential for maintaining the integrity and functionality of the micro-optic components. Micro molders must adeptly handle and package extremely small parts, a process that presents unique and complex challenges. The precision involved in micro molding for optics is of such a high degree that even the slightest deviation can render a component ineffective or flawed. Therefore, the entire process, from the initial design and molding to the final handling and packaging, must be executed with meticulous care and attention to detail. This level of expertise ensures that the micro-optic components meet the stringent performance standards required for their application in various high-tech fields. Custom Molding Machines for Micro-Optics Standard molding machines often fall short in the production of micro-optics, necessitating custom solutions. Traditional molding machines are not designed to handle the precise and intricate requirements of micro-optic components, which can include extremely small and delicate structures. The surface relief features of diffractive optical elements (DOEs), which are essential in micro-optics, can range from a few hundred nanometers to a few micrometers. This level of precision is beyond the capabilities of standard molding machines, which are generally designed for larger, less intricate parts. Additionally, refractive micro lens arrays, another crucial component in the field of micro-optics, often measure less than 100 microns. Achieving such small dimensions with high accuracy and consistency demands specialized equipment and techniques that go beyond what standard molding machines can offer. To address these challenges, companies like Accumold invest in the development and refinement of micro molding machines that can produce high-quality micro-optic parts. These machines are designed to maintain tight tolerances and ensure the precise replication of intricate surface features. This capability is essential for the production of effective DOEs and refractive micro lens arrays, which are used in a variety of applications, including medical devices, consumer electronics, and advanced imaging systems. By utilizing custom micro molding machines, manufacturers can achieve the high level of precision and quality required for micro-optics, ensuring their products meet the demanding standards of the industry. Design and Development in Micro-Optic Manufacturing Using injection molding for micro-optic manufacture involves optimizing design, mastering, tooling, and production steps, requiring close collaboration between supplier and product developer. Success in micro-optics extends beyond the molding process itself, necessitating a vertically integrated micro molding company proficient in tooling, molding, validation, and automated assembly. Additionally, expertise in Design for Manufacturability (DfM) and Design for Micro Molding (DfMM) is crucial. Micro molders often face challenges when customers present designs that are far from being producible. A proficient micro molder guides these customers toward a design that can be produced and scaled up. This process may involve simple drawing changes or a complete redesign using 3D solid modeling software. Early involvement in the design cycle is essential for optimizing the manufacturability of micro-optic components. Collaboration and Partnership in Micro Molding Healthy and rewarding relationships between micro molders and their customers are founded on strong partnerships. This collaborative approach allows micro molders to impart specialist expertise and knowledge early in the design cycle and throughout development stages. Such partnerships have been instrumental in the success of companies like Accumold, which fosters long-term relationships rather than one-off projects. The collaborative nature of the micro molding process means that successful outcomes are often the result of deep-rooted partnerships between the micro molder and the customer. This relationship allows for continuous improvement and innovation, ensuring that the final product meets the high standards required in micro-optic applications. High Stakes in Micro-Optic Manufacturing The micro-optic manufacturing sector is characterized by high costs and risks, with few qualified micro molders capable of meeting the necessary accuracy, timeframe, and cost-effectiveness. When selecting a micro molding partner, it is vital to ensure it has expert testing and quality assurance processes tailored to micro-optic fabrication. Companies must partner with firms that have a proven track record of meeting tight tolerances and exacting standards. Micro-optic components often require unique testing and quality assurance processes to validate and assess lens profiles and surface finishes. These stringent requirements highlight the importance of choosing a partner with comprehensive in-house metrology tools and expertise in micro-optic fabrication. Tooling and Validation in Micro Molding Tooling is a critical aspect of micro-optic device manufacturing. Micro molders must assist in the design, tooling, and production of various micro-optic devices, such as 250-micron fiber optic lenses, parallel array products, demux devices, and diffractive lenses. Expertise in molding attenuated resins and applying IR, anti-reflective (AR), and reflective coatings onto plastics is also essential. Precise control of molding process parameters, especially shot size or resin volume, is crucial for maintaining accuracy and repeatability in micro-optics production. Automated, hands-free assembly processes are necessary to handle tiny and delicate components, ensuring orientation is maintained and parts are uncontaminated. Advanced Assembly Techniques Micro-optic applications often benefit from over-molding, reducing the complexity of assembly operations. A micro molder skilled in over-molding can significantly streamline the production process. When post-production assembly is required, dedicated work cells can handle the entire process from molding to final packaging, especially for high-volume projects. Automated assembly processes are crucial in maintaining the integrity of micro-optic components. These processes minimize human error and contamination, ensuring that each part meets the required specifications. Over-molding techniques can further simplify assembly by integrating multiple functions into a single molded part, reducing the need for additional assembly steps. Packaging Solutions for Micro-Optics Micro-optics typically cannot be bulk packaged, necessitating various packaging methods, the most common being custom thermoform trays and tape and reel. While low-volume projects can use hand-loaded trays, high-volume projects require automated inspection and placement into packaging to ensure efficiency and quality. The delicate nature of micro-optic components means that specialized packaging solutions are necessary to protect them during transportation and storage. Custom packaging methods, such as thermoform trays, provide secure and organized storage, while automated systems ensure consistent quality and efficiency in high-volume production. Conclusion The production of micro-optics demands precision, expertise in tool construction, material selection, validation, automated assembly, and packaging. OEMs embarking on micro-optic projects must engage with experienced micro molding partners early in development to ensure accurate, timely, and cost-effective manufacturing solutions. The specialized nature of micro-optic components and the tight tolerances they require mean that only a few micro molders possess the necessary depth of experience and capability. By partnering with a qualified micro molder, OEMs can navigate the complex landscape of micro-optic manufacturing, ensuring success and innovation in their products. The role of micro molding in the production of micro-optics is pivotal, encompassing every stage from design and development to final packaging. The intricate nature of these components requires a deep understanding of the specific challenges involved, making the selection of a skilled and experienced micro molder essential for achieving the desired outcomes in this highly specialized field. www.accu-mold.com ENDS Paul Runyan is VP Sales & Marketing at Accumold. The company has grown to a 130,000 square foot fortified facility designed for assurance of supply, employs over 350 staff, and is a net exporter shipping all over the world every day from its Ankeny, IA, USA facility which runs 24 hours a day, 7 days a week.

Leading micro molding expert and innovator, Accumold, is proud to announce that it has embarked upon its 7000th customer project since it was founded back in 1985. Accumold specializes in high-precision micro molding technology, offering solutions for creating extremely small, detailed thermoplastic parts and components with micron-level precision. Its 7000 projects have been across various industries including medical, microelectronics, and automotive, emphasizing the company’s expertise in manufacturing parts requiring exacting specifications. Accumold’s long-standing experience stands it apart from suppliers that may claim a long pedigree in micro molding, but instead they have a foundation in precision engineering that goes back years, but are relatively new when it comes to actually producing micro and precision plastic parts. Paul Runyan, VP Sales & Marketing at Accumold says, “Only with decades of micro plastic part production under its belt does a micro molding supplier have the experience and strength and breadth of knowledge to tackle the most exacting of customer applications. Yours does not want to be the first project of its kind that your supplier deals with. You need longevity in manufacturing, and also evidence like we can show at Accumold that your supplier has been around the block numerous times with projects such as yours, maybe even 7000 times round the block!” Also of pivotal importance is the fact that the Accumold is truly vertically integrated, with design and material assistance, micro tool design and fabrication, micro molding, metrology and validation, and automated assembly/packaging all under one roof. This is fundamental in being able to repeatably meet the tight tolerances demanded by its customers, and mitigates the risk of losing tolerances if parts are passed from supplier to supplier. Paul Runyan, continues, “You may have looked under the hood of a micro molding supplier, and seen evidence of vertical integration. You may also have seen a relatively healthy level of experience. So far so good. But what about the size of the operation you are dealing with? Capabilities are only one part of the equation. Just as important are scalability and sustainability. Alternative suppliers may have ticked the vertical integration box, but in terms of production, is the infrastructure big enough to support your volume requirements over an extended period of time? Some customers require millions and millions of parts with a continuity of supply running over years. Put quite simply, without the space to accommodate this scale of supply and the associated manufacturing cells, then your chosen partner may be found wanting.” Accumold boasts a 130,000 square-foot advanced facility, built to guarantee supply chain security. The company is home to 350 dedicated employees and delivers its intricate parts and components to a global clientele. Because of this the company can handle the high-volume production demands of its customers, reliably delivering millions of precision parts annually. To sustain this level of supply, Accumold also has the financial robustness as a supply partner that ensures it can survive recessionary (or pandemic-associated) downturns, this continuity being vital for long-term customers. www.accu-mold.com

THE ROLE OF MICRO MOLDING IN THE MAKING OF OPTICS FOR AUGMENTED REALITY APPLICATIONS Brett Saddoris, Technical Marketing Manager, Accumold Augmented reality (AR) is rapidly advancing across industries, from consumer electronics and entertainment to healthcare and industrial sectors. Central to the functionality of AR devices are the optical components, which must meet stringent requirements to ensure clear, undistorted images and seamless digital overlays onto real-world environments. The production of these micro-optical parts has pushed the boundaries of precision manufacturing, with micro molding emerging as a key technology in meeting these demands. Optical Requirements of Augmented Reality Optics used in AR devices, such as tiny lenses, light guides, and diffractive optical elements (DOEs), must adhere to extremely tight tolerances to ensure high image clarity and precise alignment. Given the short optical paths in AR systems, even the slightest deviation in the position or shape of these components can lead to significant image distortions or misalignment. This is particularly crucial in devices like AR smart glasses, where the augmented image must perfectly overlay the user’s view of the physical world. Micro molding addresses this challenge by offering a level of precision that meets the demanding positional and surface finish requirements of AR optics. The components can be manufactured with micron-level accuracy, which ensures that the optical elements are perfectly aligned and function as intended. Moreover, micro-molded parts can achieve the high surface quality necessary to minimize light scattering, which is essential for maintaining image clarity. Imperfections on the surface of optical elements can degrade image quality, so producing parts with tight profile tolerances is critical to the overall performance of AR systems. Another important factor is the miniaturization required in AR devices. These systems, especially those worn on the head or integrated into smart glasses, must be lightweight and compact. Micro molding enables the production of extremely small components, often ranging from 20 microns to 1 mm in size, as well as larger components with micron-level features. The ability to produce such tiny, complex parts without compromising on optical performance is one of the key reasons why micro molding is indispensable for AR applications. Precision in Micro Molding for Micro-Optics The fabrication of micro-optic components demands an exceptional level of precision that can only be provided by specialized micro molding companies. This process is far more intricate than the molding of typical mechanical parts due to the delicate nature and complexity of micro-optic components. For AR applications, where optical performance is paramount, even the slightest deviation in a part's dimensions or surface quality can render it ineffective or flawed. Achieving the required tolerances for micro-optic parts involves advanced expertise in molding processes, materials, and tooling. Micro molders must have a deep understanding of the unique challenges posed by optical components, from maintaining tight tolerances during the molding process to ensuring that the final parts meet the high optical standards required. This is particularly true for complex features like surface relief patterns in diffractive optical elements, which can be just a few hundred nanometers in size. These intricate features must be replicated with absolute precision to ensure that the optical component functions as intended. In addition to the precision of the molding process, micro molders must handle and package these extremely small parts with care, as they are highly fragile and susceptible to damage during post-production handling. This requires specialized knowledge and equipment to ensure that the integrity of the micro-optic components is maintained throughout the manufacturing and packaging process. Custom Molding Machines for Micro-Optics Standard injection molding machines are generally not able to produce micro-optic components due to the high level of precision and small scale involved. Micro-optic parts, such as refractive lens arrays and DOEs, often require custom molding machines designed specifically to handle these intricate structures. These machines are equipped with advanced features that allow for the precise replication of small optical elements with micron-level accuracy. For example, refractive micro lens arrays used in AR applications often measure less than 100 microns, and the production of such components requires specialized techniques that go beyond the capabilities of standard machines. Similarly, DOEs, which are crucial for controlling light in AR devices, have surface features measured in nanometers, and their successful production relies on molding machines that can maintain tight control over process parameters, such as shot size and material flow. Companies like Accumold have developed custom micro molding machines that are capable of producing high-quality optical parts with the accuracy and consistency needed for AR applications. These machines are specifically designed to meet the challenges of micro-optics manufacturing, ensuring that each part meets the stringent performance standards required in high-tech fields such as AR, medical diagnostics, and advanced imaging systems. Design and Development in Micro-Optic Manufacturing The successful production of micro-optics for AR devices goes beyond the molding process itself and involves close collaboration between the micro molder and the product developer from the very beginning of the design phase. Early involvement in the design cycle allows micro molders to optimize the manufacturability of optical components, ensuring that they can be produced to the required specifications and scaled up for mass production. Design for Manufacturability (DfM) and Design for Micro Molding (DfMM) principles are essential in this process. These design approaches help avoid common pitfalls that can arise when customers present designs that are not optimized for micro molding. For example, minor adjustments to the geometry or material selection of an optical component can significantly improve its manufacturability and reduce production costs. Micro molders work closely with their customers to guide the design process, using advanced tools such as 3D solid modeling software to refine designs and ensure that they can be produced efficiently. This collaborative approach is crucial for achieving the best possible outcome in the production of AR optics, where precision and functionality are paramount. Applications of Micro Molding in AR Devices Micro molding plays a crucial role in various AR applications by enabling the production of the small, precise optical components that these devices rely on. One notable application is head-up displays (HUDs) used in automotive and aviation sectors. These displays project important information, such as speed and navigation data, onto the windshield, allowing the driver or pilot to access vital information without diverting their attention from the road or sky. Micro-molded lenses and light guides are essential for ensuring that the projected image is clear and properly aligned with the user’s line of sight. Another key application is in AR smart glasses, which are designed to overlay digital content onto the wearer’s real-world view. These devices require optical components that are not only highly precise but also compact and lightweight, as they must be worn comfortably for extended periods. Micro molding enables the production of the tiny lenses and light guides needed to create these devices, all while maintaining the optical quality required for a seamless AR experience. In medical applications, AR systems are used to overlay imaging data onto a patient during surgery or diagnosis, helping medical professionals to visualize internal structures in real time. The optics used in these systems must be extremely precise, as any distortion in the image could lead to diagnostic errors or surgical complications. Micro molding provides the precision and reliability needed to ensure that these optics function correctly in such critical applications. Overcoming Challenges in Micro-Optic Production While micro molding offers many advantages in the production of AR optics, there are also challenges that must be addressed to achieve successful outcomes. One of the primary challenges is tooling, which must be designed with extreme precision to produce the complex geometries and surface features required for micro-optic components. The development of high-precision molds is a critical step in ensuring that the final parts meet the necessary optical standards, and necessitates working with a micro molder that has in-house micro tool fabrication expertise. Material selection is another challenge, as the polymers used for AR optics must offer both optical clarity and durability. In addition, they must be capable of maintaining their properties over time, even when exposed to environmental factors such as UV light and humidity. Micro molding allows for the use of advanced optical materials, including polymers that are specifically formulated for optical applications. In addition, the assembly of AR devices that incorporate micro-optic components is often complex, as these parts are extremely small and delicate. To mitigate this challenge, micro molders should use automated assembly techniques that reduce the risk of contamination and ensure precise alignment of the components. Over-molding, a technique in which multiple functions are integrated into a single molded part, is also used to simplify assembly and reduce the need for additional post-production steps.