Precision replication and quality analysis of the molded glass cylindrical lens array

Precision glass molding (PGM) is a well-established and cost-effective manufacturing process used to fabricate high-quality and high-precision optical elements with complex geometries, such as aspherical lens, microlens array, and microprisms. This study focuses on the replication quality of molded glass cylindrical lens arrays, which is critical for achieving exceptional precision and consistency in optical applications. The effect of process parameters on replication quality of the molded cylindrical lens array was studied. A 4 × 1 cylindrical lens array, fabricated using wire electrical discharge machining and polishing, served as the replication mold. The profile deviation and replication ratio were analyzed under different processing conditions using a surface profilometer, while optical quality was assessed through birefringence measurements and light transmission experiments. The results indicated that integrated control of molding parameters is vital for high-fidelity replication, with optimal conditions yielding a height deviation of approximately 4 nm and a filling ratio of 99.999% at 550 °C and 9.8 kN. Additionally, we observed that increased molding force reduces height deviation, while excessive molding temperatures can lead to increased profile deviation. The minimum profile deviation achieved was below 1 µm, and residual birefringence was found to be less than 10 nm. This work not only enhances the understanding of precision glass molding but also provides valuable insights for manufacturers to identify and mitigate potential defects, ultimately improving product reliability and supporting innovation in optical design.