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Precision replication and quality analysis of the molded glass cylindrical lens array
Optics Express
|August 13, 2025
Summary
Precision glass molding (PGM) achieves high-fidelity replication of cylindrical lens arrays. Optimal control of molding parameters yields minimal height deviation and high filling ratios for advanced optical applications.
Area of Science:
- Materials Science
- Optical Engineering
- Manufacturing Processes
Background:
- Precision glass molding (PGM) is a key technique for creating complex optical elements like aspherical lenses and microlens arrays.
- Replication quality of molded glass cylindrical lens arrays is crucial for consistent optical performance.
Purpose of the Study:
- To investigate the impact of process parameters on the replication quality of molded glass cylindrical lens arrays.
- To identify optimal conditions for high-fidelity replication in PGM.
Main Methods:
- A 4x1 cylindrical lens array mold was fabricated using wire electrical discharge machining and polishing.
- Surface profilometry was used to analyze profile deviation and replication ratio.
- Birefringence measurements and light transmission experiments assessed optical quality.
Main Results:
- Optimal molding conditions (550 °C, 9.8 kN) resulted in a height deviation of ~4 nm and a filling ratio of 99.999%.
- Increased molding force reduced height deviation; excessive molding temperature increased profile deviation.
- Minimum profile deviation was <1 µm, with residual birefringence <10 nm.
Conclusions:
- Integrated control of PGM parameters is essential for high-fidelity replication of optical elements.
- Findings provide manufacturers with insights to mitigate defects and enhance product reliability.
- This research supports innovation in optical design through improved PGM understanding.
