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Additive manufacturing of double-sided centimeter-scale optics.

Markku Pekkarinen, Petri Karvinen, Jyrki Saarinen

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    This summary is machine-generated.

    Rapid manufacturing of double-sided optics is achieved using additive manufacturing (AM). Two methods, support material and flipping, produce centimeter-scale optics with high surface quality for illumination applications without post-processing.

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    Area of Science:

    • Optics and Photonics
    • Materials Science
    • Manufacturing Engineering

    Background:

    • High-quality optical components are crucial for illumination systems.
    • Traditional manufacturing methods for double-sided optics can be complex and time-consuming.
    • Additive manufacturing offers potential for rapid, high-precision component fabrication.

    Purpose of the Study:

    • To demonstrate rapid, post-processing-free manufacturing of double-sided, centimeter-scale optics.
    • To present and compare two additive manufacturing approaches for optical component production.
    • To evaluate the surface quality and form accuracy of the manufactured optics.

    Main Methods:

    • Additive manufacturing (AM) utilizing an optically transparent material.
    • Employing a water-soluble support material for single-process fabrication (support method).
    • Utilizing a single optically transparent material with mid-process flipping (flipping method).

    Main Results:

    • Both support and flipping methods yielded centimeter-scale optics without post-processing.
    • Achieved surface roughness (Rq) of 11.48 ±3.32 nm.
    • Attained form accuracy of ±10 μm, suitable for illumination optics.

    Conclusions:

    • Additive manufacturing provides a rapid route to producing illumination-quality double-sided optics.
    • The support method offers advantages in alignment and potential for future complex designs.
    • The flipping method simplifies material requirements, while both methods achieve necessary optical surface quality.