Replication of thermoplastic polymer spherical lens array using microforged molding technique.

The study uses Si3N4 ceramic balls as indentors to create the mold. These balls have a diameter of 3.5 mm and a surface roughness of 10 nm. The researchers optimize heating and de-molding temperatures to improve mold quality. They also adjust indentation force and holding time during the process. The mold is then used to fabricate PMMA lens arrays through hot embossing. The team evaluates the dimensional stability of the final product. They measure surface features and optical performance to assess quality. The study compares the new method to traditional approaches in terms of accuracy and cost.

The optimized mold showed excellent dimensional stability and surface features. The PMMA lens arrays produced had high optical performance. The deep sag height and low f/# requirements were met effectively. The microforging technique reduced errors caused by deformation. The self-alignment mode of the balls and cavities improved positioning accuracy. The contact pressure was distributed symmetrically during the process. The method proved to be cost-effective and suitable for mass production. The results suggest that this technique outperforms previous methods in several key areas.

The proposed microforging technique offers a viable solution for manufacturing thermoplastic polymer spherical lens arrays. The method simplifies the production process and reduces costs. The self-alignment feature ensures accurate positioning of the lens elements. The study demonstrates that the technique can meet high optical performance standards. The uniform deformation of the pre-milled cavities improves overall quality. The researchers suggest that this method is ideal for large-scale production. The results support the use of microforging as an alternative to traditional techniques. The study highlights the potential of this approach for future optical manufacturing.