Additive manufacturing of optical components

Abstract

aThe authors are all members of the optical metrology group at the Center for Optical Technologies at Aalen University. Since 2013, the focus of the group is on the additive manufacturing of optical components -transmissive optics, as well as reflective optics. The aim of the group is to find new solutions in the field of optical metrology and lighting through new design approaches, which are possible due to the additive manufacturing. Abstract:The development of additive manufacturing methods has enlarged rapidly in recent years. Thereby, the work mainly focuses on the realization of mechanical components, but the additive manufacturing technology offers a high potential in the field of optics as well. Owing to new design possibilities, completely new solutions are possible. This article briefly reviews and compares the most important additive manufacturing methods for polymer optics. Additionally, it points out the characteristics of additive manufactured polymer optics. Thereby, surface quality is of crucial importance. In order to improve it, appropriate post-processing steps are necessary (e.g. robot polishing or coating), which will be discussed. An essential part of this paper deals with various additive manufactured optical components and their use, especially in optical systems for shape metrology (e.g. borehole sensor, tilt sensor, freeform surface sensor, fisheye lens). The examples should demonstrate the potentials and limitations of optical components produced by additive manufacturing.

3D printed optics with nanometer scale surface roughness

“…By lifting these constraints and providing integrated solutions that can be manufactured cost effectively even in small series, 3D printing has the potential to revolutionize design, prototyping, and fabrication of optical systems. To realize this potential, 3D printing must be refined to meet the needs of optical devices [13][14][15] . 3D printing is implemented in a variety of technologies including Direct Metal Laser Sintering, extrusion as in Fused Deposition Modeling and Fused Filament Fabrication, lamination as in Laminated Object Manufacturing, Drop-on-Demand (DoD) inkjet type printing where a wax like substance is jetted as micro-droplets, and polymerization through StereoLithography Apparatus (SLA).…”

IR-laser assisted additive freeform optics manufacturing

“…4(c) and (d) are two other freeform optics examples showing the range of AFOM. Compared to the yellowish UV curable lenses reported in various publications 13 , the lenses in Fig. 4 are optically clear, not showing any yellowness, much better for imaging applications.…”

“…Each of these commercial systems uses an ultraviolet (UV) curing method, either as a standard UV polymerization or two-photon polymerization process. One limitation of the current UV curing systems is the material, which causes the lens to appear yellowish 13 .…”

3D photo-responsive optical devices manufactured by advanced printing technologies

“…Nevertheless, even standard UV STL has been used for successfully printing various optical components, such as aspheric lenses, mirrors and optical guides operating in the visible range. [17][18][19] In this framework, a current challenge is to develop photo-curable materials and printing methods, that are suitable to achieve optically-active components, namely systems which can feature some specific optical properties (i.e. emission at well-defined spectral bands, nonlinear and time-changing properties, etc.).…”