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Precision Replication of Micro-Optics Through Injection Molding. David Gill -- Dr. Thomas Dow -- Alex Sohn. Precision Engineering Center -North Carolina State University. Project Goals. Accurately Replicate Micro-Optics Using the Injection Molding Process

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precision replication of micro optics through injection molding
Precision Replication of Micro-Optics Through Injection Molding

David Gill -- Dr. Thomas Dow -- Alex Sohn

Precision Engineering Center -North Carolina State University

project goals
Project Goals
  • Accurately Replicate Micro-Optics Using the Injection Molding Process
  • Find The Injection Molding Factors That Have the Greatest Effect on the Replication of Micro-Optics

Blaze Grating

Dimensions in nm

presentation outline
Presentation Outline
  • Injection Molding Process Factors
  • Design of Experiment Process Factors ==> Replication Fidelity
  • Micro-Optics Features
  • Research Results
nissei hm 7
Nissei HM-7
  • Machine Characteristics
  • 6.2 cm3 Shot Size
  • 102 mm Tie Bar Spacing
  • 7 Ton Clamping Force
  • Hydraulic Actuation
  • Water Based Mold Temperature Control
slide6

Mold

Barrel

Screw

Injection

Hold

Injection Molding Process Factors

design of experiment

28x4 = 1024 Tests

32 Tests

DOE

Design of Experiment
  • Selected a High and Low Value for Each Factor
  • Both Values Must Create a Measurable Part

(More Than 3000 Parts)

Assumptions

- Linear Response Between Factor Values

- No Interaction Between Factors

micro optic features
Micro-Optic Features

Depth

Aspect Ratio =

Width

feature measurements
Feature Measurements

Astigmatism

Coma

Spherical Aberration

Residual RMS

Residual PV

Grating Step Height

Wedding Cake Step Height

Phase Interferometer

White Light Interferometer

Stylus Profilometer

replication fidelity achieved
Blaze Grating: Step Height Error

112 nm (7%)

127 nm

Replication Fidelity Achieved

Fresnel: Residual RMS Error

76 nm

Sphere: Residual RMS Error

Wedding Cake: Step Height Error

1.8µm (0.9%)

fresnel replication
Fresnel Replication

1mm

Mold

PMMA Lens

blaze grating

Mold 2500x

Mold 1000x

PMMA 2500x

PMMA 1000x

Blaze Grating

50µm

20µm

summary
Summary
  • Injection Molding Process and Factors in Molding
  • Design of Experiment
  • Micro-Optical Features and Measurement Methods
  • Results of the DOE
  • Confirmation of the Results
conclusions
Conclusions
  • Repeatable Replication of Micro-Optics is Possible Using Injection Molding
  • Molding Factors Influence the Replicated Shape of Micro-Optics
  • Mold Temperature and Screw Rotation Speed Have the Greatest Impact on Replication Fidelity

The authors wish to acknowledge the support of this research by the National Science Foundation

(grant #9908223, Dr. K. P. Rajurkar, Program Director)