Characterization of process and machine dynamics on the precision replication of microlens arrays using microinjection moulding

doi:10.1007/s40436-020-00341-y

Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (3): 319-341.doi: 10.1007/s40436-020-00341-y

• • 下一篇

Characterization of process and machine dynamics on the precision replication of microlens arrays using microinjection moulding

Hao-Yang Zhang^1,2, Nan Zhang², Wei Han³, Hong-Gang Zhang², Michael D. Gilchrist², Feng-Zhou Fang^1,2

1 State Key Laboratory of Precision Measuring Technology and Instruments, Laboratory of MicroNano Manufacturing Technology(MNMT), Tianjin University, Tianjin 300072, People's Republic of China;
2 Centre of MicroNano Manufacturing Technology(MNMT-Dublin), School of Mechanical and Materials Engineering, University College Dublin, Belfield, Dublin 4, Ireland;
3 Key Laboratory of Computational Optical Imaging Technology, Chinese Academy of Sciences, Beijing 100094, People's Republic of China

收稿日期:2020-08-04 修回日期:2020-10-31 出版日期:2021-09-25 发布日期:2021-09-13
通讯作者: Nan Zhang, Feng-Zhou Fang E-mail:nan.zhang@ucd.ie;fzfang@tju.edu.cn
基金资助:
The support from the National Key Research & Development Program (Grant No. 2016YFB1102203), the China Scholarship Council, the National Natural Science Foundation of China (Grant No. 61675149) and Science Foundation Ireland (Grant No. 15/RP/B3208) is gratefully acknowledged.

Characterization of process and machine dynamics on the precision replication of microlens arrays using microinjection moulding

Hao-Yang Zhang^1,2, Nan Zhang², Wei Han³, Hong-Gang Zhang², Michael D. Gilchrist², Feng-Zhou Fang^1,2

1 State Key Laboratory of Precision Measuring Technology and Instruments, Laboratory of MicroNano Manufacturing Technology(MNMT), Tianjin University, Tianjin 300072, People's Republic of China;
2 Centre of MicroNano Manufacturing Technology(MNMT-Dublin), School of Mechanical and Materials Engineering, University College Dublin, Belfield, Dublin 4, Ireland;
3 Key Laboratory of Computational Optical Imaging Technology, Chinese Academy of Sciences, Beijing 100094, People's Republic of China

Received:2020-08-04 Revised:2020-10-31 Online:2021-09-25 Published:2021-09-13
Supported by:
The support from the National Key Research & Development Program (Grant No. 2016YFB1102203), the China Scholarship Council, the National Natural Science Foundation of China (Grant No. 61675149) and Science Foundation Ireland (Grant No. 15/RP/B3208) is gratefully acknowledged.

摘要/Abstract

摘要： Injection moulding has shown its advantages and prevalence in the production of plastic optical components, the performance and functionality of which rely on the precision replication of surface forms and on minimizing residual stress. The present work constitutes a systematic and comprehensive analysis of practical microlens arrays that are designed for light-field applications. Process parameters are screened and optimized using a two-stage design of experiments approach. Based on in-line process monitoring and a quantitative and qualitative evaluation being carried out in terms of geometric accuracy, surface quality and stress birefringence, the replication is shown to relate directly to machine settings and dynamic machine responses. The geometric accuracy and stress birefringence are both largely associated with screw displacement and peak cavity pressure during the packing stage, while surface quality is closely related to cavity temperature. This study provides important insights and recommendations regarding the overall replication quality of microlens arrays, while advanced injection moulding solutions may be necessary to further improve the general replication quality.

The full text can be downloaded at https://link.springer.com/article/10.1007%2Fs40436-020-00341-y

关键词: Optics, Process monitoring, Form, Roughness, Residual stress, Sensor

Abstract: Injection moulding has shown its advantages and prevalence in the production of plastic optical components, the performance and functionality of which rely on the precision replication of surface forms and on minimizing residual stress. The present work constitutes a systematic and comprehensive analysis of practical microlens arrays that are designed for light-field applications. Process parameters are screened and optimized using a two-stage design of experiments approach. Based on in-line process monitoring and a quantitative and qualitative evaluation being carried out in terms of geometric accuracy, surface quality and stress birefringence, the replication is shown to relate directly to machine settings and dynamic machine responses. The geometric accuracy and stress birefringence are both largely associated with screw displacement and peak cavity pressure during the packing stage, while surface quality is closely related to cavity temperature. This study provides important insights and recommendations regarding the overall replication quality of microlens arrays, while advanced injection moulding solutions may be necessary to further improve the general replication quality.

The full text can be downloaded at https://link.springer.com/article/10.1007%2Fs40436-020-00341-y

Key words: Optics, Process monitoring, Form, Roughness, Residual stress, Sensor

Hao-Yang Zhang, Nan Zhang, Wei Han, Hong-Gang Zhang, Michael D. Gilchrist, Feng-Zhou Fang. Characterization of process and machine dynamics on the precision replication of microlens arrays using microinjection moulding[J]. Advances in Manufacturing, 2021, 9(3): 319-341.

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Characterization of process and machine dynamics on the precision replication of microlens arrays using microinjection moulding

Characterization of process and machine dynamics on the precision replication of microlens arrays using microinjection moulding

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