Scalable and energy-saving manufacturing approach for monolithic polymer components

Frank C. Wippermann; Jacques W. Duparré; Nico Hagen

doi:10.1117/12.2675084

7 August 2023 Scalable and energy-saving manufacturing approach for monolithic polymer components

Frank C. Wippermann, Jacques W. Duparré, Nico Hagen

Proceedings Volume 12624, Digital Optical Technologies 2023; 126240Q (2023) https://doi.org/10.1117/12.2675084
Event: SPIE Digital Optical Technologies, 2023, Munich, Germany

Abstract

We propose a scalable and energy-saving technology for monolithic polymer components such as aspherical lenses. UVreplication is well known from wafer level optics, where supporting glass wafers remain in the final lens severely limiting the degrees of freedom of the optical design. In addition, material shrinkage when the curing the polymer limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our approach, the glass substrate in the individual lenses is omitted and a compensation of the shrinkage is achieved with minimum form error. This enables sag heights and aspherical lens profiles on both sides of thin menisci as required in high-resolution imaging optics so far realized by injection molding only. In contrast to injection molding, the replication is carried out at room temperature which saves energy and leads to a more eco-friendly production. In addition, low-cost materials for molds and lens masters can be used so that demonstrators, prototypes, small series and products in medium volumes of complex imaging systems can now be addressed economically for the first time. These smaller manufacturing volumes were so far limited to spherical glass lenses with their known drawbacks with respect to complexity and miniaturization compared to aspheres. In addition, the used materials are compliant to high temperature requirements even surviving reflow-soldering performed at 260°C. We present details of our new technology at the example of realized demo systems towards highvolume, low-cost and high-performance lens stacks ultimately targeting mobile imaging applications.

Citation Download Citation

Frank C. Wippermann, Jacques W. Duparré, and Nico Hagen "Scalable and energy-saving manufacturing approach for monolithic polymer components", Proc. SPIE 12624, Digital Optical Technologies 2023, 126240Q (7 August 2023); https://doi.org/10.1117/12.2675084

ACCESS THE FULL ARTICLE

INSTITUTIONAL
Select your institution to access the SPIE Digital Library.

SELECT YOUR INSTITUTION

PERSONAL
Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.

PERSONAL SIGN IN

No SPIE Account? Create one

PURCHASE THIS CONTENT

SUBSCRIBE TO DIGITAL LIBRARY

50 downloads per 1-year subscription

Members: $195

Non-members: $335 ADD TO CART

25 downloads per 1 - year subscription

Members: $145

Non-members: $250 ADD TO CART

PURCHASE SINGLE ARTICLE

Includes PDF, HTML & Video, when available

Members: $17.00

Non-members: $21.00 ADD TO CART

PROCEEDINGS
6 PAGES

DOWNLOAD PAPER SAVE TO MY LIBRARY

GET CITATION

RIGHTS & PERMISSIONS

Get copyright permission Get copyright permission on Copyright Marketplace

KEYWORDS

Lenses

Polymers

Wafer level optics

Injection molding

Manufacturing

Glasses

Endoscopy

Show All Keywords

Keywords/Phrases

Search In:

Publication Years