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

doi:10.1007/s40436-020-00341-y

Abstract

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.

TrendMD

References

1. Huang C, Li L, Yi AY (2009) Design and fabrication of a micro Alvarez lens array with a variable focal length. Microsyst Technol 15(4):559-563
2. Fang FZ, Zhang N, Zhang X (2016) Precision injection molding of freeform optics. Adv Opt Technol 5(4). https://doi.org/10.1515/aot-2016-0033
3. Cirino GA, Granado RM, Mohammed-Brahim T et al (2017) Assessment of replication fidelity of optical microstructures by hot embossing. Int J Adv Manuf Technol 88(1/4):303-316
4. Zhang HY, Fang FZ, Gilchrist MD et al (2018) Filling of high aspect ratio micro features of a microfluidic flow cytometer chip using micro injection moulding. J Micromech Microeng 28(7):075005
5. Xue B, Geng Y, Wang D et al (2019) Improvement in surface quality of microchannel structures fabricated by revolving tipbased machining. Nanomanuf Metrol 2(1):26-35
6. Cai Y, Xu Z, Wang H et al (2019) A sequential process for manufacturing nature-inspired anisotropic superhydrophobic structures on AISI 316L stainless steel. Nanomanuf Metrol 2(3):148-159
7. Chen J, Cheng J, Zhang D et al (2016) Precision UV imprinting system for parallel fabrication of large-area micro-lens arrays on non-planar surfaces. Precision Eng 44:70-74
8. Hou T, Zheng C, Bai S et al (2015) Fabrication, characterization, and applications of microlenses. Appl Opt 54(24):7366-7376
9. Pang K, Song L, Fang FZ et al (2016) An imaging system with a large depth of field based on an overlapped micro-lens array. CIRP Annals Manuf Technol 65(1):471-474
10. Bäumer S (2010) Handbook of plastic optics, Wiley Online Library, Hoboken
11. Li S, Yuan Y, Liu B et al (2018) Influence of microlens array manufacturing errors on light-field imaging. Opt Commun 410:40-52
12. Stevens RF, Miyashita T (2010) Review of standards for microlenses and microlens arrays. Imaging Sci J 58(4):202-212
13. Guevara-Morales A, Figueroa-López U (2014) Residual stresses in injection molded products. J Mater Sci 49(13):4399-4415
14. Manaf ARA, Yan J (2017) Improvement of form accuracy and surface integrity of Si-HDPE hybrid micro-lens arrays in press molding. Precision Eng 47:469-479
15. Dick L, Risse S, Tunnermann A (2012) Injection molded high precision freeform optics for high volume applications. Adv Opt Technol 1(3):39-50
16. Lou C, Chiang Y, Cheng H et al (2011) A novel and rapid fabrication for microlens arrays using microinjection molding. Polym Eng Sci 51(2):391-402
17. Weng C, Lee WB, To S (2009) Birefringence techniques for the characterization of residual stresses in injection-moulded microlens arrays. Polym Testing 28(7):709-714
18. Tsai K, Hsieh C, Lo W (2009) A study of the effects of process parameters for injection molding on surface quality of optical lenses. J Mater Process Technol 209(7):3469-3477
19. Kirchberg S, Chen L, Xie L et al (2012) Replication of precise polymeric microlens arrays combining ultra-precision diamond ball-end milling and micro injection molding. Microsyst Technol 18(4):459-465
20. Weng C, Lee WB, To S (2010) A study of the relevant effects on the maximum residual stress in the precision injection moulding of microlens arrays. J Micromech Microeng 20(3):035033
21. Montgomery DC (2017) Design and analysis of experiments, Wiley, Hoboken
22. Kamal MR, Isayev AI, Liu SJ (2009) Injection molding:technology and fundamentals, Hanser Gardner Publications, Munich
23. Macías C, Meza O, Pérez E (2015) Relaxation of residual stresses in plastic cover lenses with applications in the injection molding process. Eng Fail Anal 57:490-498
24. Lee YB, Kwon TH, Yoon K (2002) Numerical prediction of residual stresses and birefringence in injection/compression molded center-gated disk. Part I:Basic modeling and results for injection molding. Polymer Eng Sci 42(11):2246-2272
25. Ramesh K (2000) Digital photoelasticity:advanced techniques and applications, 2000, Springer, Berlin
26. Zhang N, Gilchrist M (2012) Characterization of thermo-rheological behavior of polymer melts during the micro injection moulding process. Polym Testing 31(6):748-758
27. Kobayashi T, Sera H, Wakabayashi T et al (2018) Surface flattening and nanostructuring of steel by picosecond pulsed laser irradiation. Nanomanuf Metrol 1(4):217-224
28. Michaeli W, Heßner S, Klaiber F et al (2007) Geometrical accuracy and optical performance of injection moulded and injection-compression moulded plastic parts. CIRP Ann Manuf Technol 56(1):545-548
29. Kayano Y, Zouta K, Takahagi S et al (2011) Replication properties and structure of PC in micromolding with heat insulator mold using zirconia ceramic. Int Polym Proc 26(3):304-312
30. Siegmann A, Buchman A, Kenig S (1982) Residual stresses in polymers III:The influence of injection-molding process conditions. Polym Eng Sci 22(9):560-568
31. Zhang N, Choi SY, Gilchrist MD (2014) Flow induced crystallization of poly (ether-block-amide) from the microinjection molding process and its effect on mechanical properties. Macromol Mater Eng 299(11):1362-1383
32. Lai HE, Wang PJ (2008) Study of process parameters on optical qualities for injection-molded plastic lenses. Appl Opt 47(12):2017-2027
33. Zhang N, Zhang HY, Stallard CP et al (2018) Replication integrity of micro features using variotherm and vacuum assisted microinjection moulding. CIRP J Manuf Sci Technol 23:20-38

[1]	Hao Sun, Sheng-Qiang Zhao, Fang-Yu Peng, Rong Yan, Xiao-Wei Tang. Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes [J]. Advances in Manufacturing, 2025, 13(3): 584-605.
[2]	Angela Cusanno, Pasquale Guglielmi, Donato Sorgente, Gianfranco Palumbo. Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part [J]. Advances in Manufacturing, 2025, 13(2): 284-302.
[3]	Wen Wang, Hao Hu, Xiao-Wei Luo, Shi-Shu Ding. Blockchain-enabled platform for the quality management of the ready-mixed concrete supply chain [J]. Advances in Manufacturing, 2025, 13(2): 362-376.
[4]	Chang-Feng Yao, Yun-Qi Sun, Liang Tan, Min-Chao Cui, Ding-Hua Zhang, Jun-Xue Ren. Investigation of control method on blade shape accuracy of blisk in vibration finishing [J]. Advances in Manufacturing, 2025, 13(2): 377-394.
[5]	Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Chuan Qian, Zi-Ang Liu, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu. Grinding of particle-reinforced metal matrix composite materials: current status and prospects [J]. Advances in Manufacturing, 2025, 13(1): 43-68.
[6]	Zhen-Jing Duan, Shuai-Shuai Wang, Shu-Yan Shi, Ji-Yu Liu, Yu-Heng Li, Zi-Heng Wang, Chang-He Li, Yu-Yang Zhou, Jin-Long Song, Xin Liu. Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy [J]. Advances in Manufacturing, 2025, 13(1): 69-87.
[7]	Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Dao-Hui Xiang, Zi-Ang Liu, Chuan Qian, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu. Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation [J]. Advances in Manufacturing, 2025, 13(1): 88-104.
[8]	Yang Lu, Jian-Xin Deng, Zhi-Hui Zhang, Jia-Xing Wu, Ran Wang, Yi-Chen Bao. Cutting performance of saw blades with microtextured rougher and finisher sawteeth [J]. Advances in Manufacturing, 2024, 12(2): 317-334.
[9]	Jin Zhang, Li Ling, Qian-Yue Wang, Xue-Feng Huang, Xin-Zhen Kang, Gui-Bao Tao, Hua-Jun Cao. Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform [J]. Advances in Manufacturing, 2024, 12(2): 349-364.
[10]	Wei Li, Liang-Chi Zhang, Chu-Han Wu, Yan Wang, Zhen-Xiang Cui, Chao Niu. A data-driven approach to RUL prediction of tools [J]. Advances in Manufacturing, 2024, 12(1): 6-18.
[11]	Dien Hu, Jieyichen Fang, Feng Zeng, Ming-Wang Fu. Grain size effect on the assembly quality of micro-scaled barrel formed by microforming [J]. Advances in Manufacturing, 2024, 12(1): 19-32.
[12]	Meng-Meng Liu, Yu-Li Liu, Heng Li. Insight into deformation allocation in the multi-pass roll forming of a double-walled brazed tube [J]. Advances in Manufacturing, 2023, 11(4): 567-586.
[13]	Lai Hu, Jun Zha, Wei-Hua Zhao, Xiao-Fei Peng, Yao-Long Chen. Multi-dimensional controllability analysis of precision ball bearing integrity [J]. Advances in Manufacturing, 2023, 11(4): 682-693.
[14]	Xue-hong Shen, Chang-Feng Yao, Liang Tan, Ding-Hua Zhang. Prediction model of surface integrity characteristics in ball end milling TC17 titanium alloy [J]. Advances in Manufacturing, 2023, 11(3): 541-565.
[15]	Jon Martin Fordal, Per Schj?lberg, Hallvard Helgetun, Tor ?istein Skjermo, Yi Wang, Chen Wang. Application of sensor data based predictive maintenance and artificial neural networks to enable Industry 4.0 [J]. Advances in Manufacturing, 2023, 11(2): 248-263.