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Precision glass molding of diffractive optical elements with high surface quality.

Yingying Zhang, Rongguang Liang, Oliver Joshua Spires

    Optics Letters
    |December 1, 2020
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    Summary

    Researchers developed a novel fabrication method for high-quality glass diffractive optics. This technique overcomes previous molding challenges, enabling precise and durable optical components for advanced applications.

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    Area of Science:

    • Optics and Photonics
    • Materials Science and Engineering
    • Manufacturing Technology

    Background:

    • Diffractive optical surfaces offer advantages like weight reduction and chromatic aberration correction in optical systems.
    • Fabrication of high-quality glass diffractive optics is difficult, limiting commercial use.
    • Existing methods face challenges in achieving desired surface quality and durability.

    Purpose of the Study:

    • To develop and demonstrate a fabrication method for high-surface-quality diffractive glass optics.
    • To address challenges in molding diffractive optics at elevated temperatures (up to 550°C).
    • To optimize mold material selection, fabrication, and precision glass molding processes.

    Main Methods:

    • Selection of mold material: Nickel phosphorous (NiP) plating for cutting performance and anti-adhesion, and copper-nickel C71500 (CuNi) substrate for thermal expansion compatibility.
    • Mold fabrication and precision glass molding techniques optimized for high-temperature applications.
    • Evaluation of mold durability and stability during the molding process.

    Main Results:

    • Successful fabrication of diffractive glass optics using the developed method.
    • Achieved a surface roughness of 2 nm Sa for the diffractive glass optics.
    • Demonstrated the effectiveness of NiP plating and CuNi substrate in overcoming molding challenges.

    Conclusions:

    • The proposed fabrication method enables the production of high-surface-quality diffractive glass optics.
    • The optimized mold material selection and process parameters are crucial for successful high-temperature molding.
    • This advancement facilitates wider adoption of diffractive optics in commercial applications.