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A homemade apparatus was used to apply ultrasonic-vibration to assist the glass hot embossing processes. To operate at high temperatures for glass hot embossing, the ultrasonic vibration system was appropriately designed with an embedded cooling system, and an ultrasonic horn was specifically modified for hightemperature use. Molds with both V-groove and Fresnel structures were manufactured for hot embossing experiments on PSK-100 glass. The heights of the molded structures were increased significantly with the assistance of ultrasonic vibration. This technology demonstrates the capability to upgrade the performance of the glass hot embossing process.

This research integrated finite element analysis (FEA) and optimum design to obtain a fast, accurate and automatic optimization system for the design of an ultrasonic horn. The optimization system was developed to achieve uniform amplitude distribution on the output surface of a block shaped horn for the ultrasonic plastic welding. Agreement between the experimental and numerical data proved that this optimization system was efficient in the design of ultrasonic horns.

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