Scalability of the precision glass molding process for an efficient optics production

Liu, Gang; Staasmeyer, Jan-Helge; Grunwald, Tim; Dambon, Olaf

doi:10.1117/12.2321103

Cited by 1 publication

(2 citation statements)

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“…The use of multi-cavity molds represents an economically, scientifically and ecologically interesting possibility for advancing nonisothermal glass molding. For this purpose, first developments have already been made in the field of PGM, which take into account both several individual cavities and a wafer-scale arrangement [12,13]. By using multiple cavities, a large number of optics can be produced in one press cycle.…”

Section: Fig 3 Process Chain Of the Rod Pressing Processmentioning

confidence: 99%

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Enabling Sustainability in Glass Optics Manufacturing by Wafer Scale Molding

Strobl

Vogel

et al. 2022

KEM

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Numerous optical applications have rising demands for ever increasing quantities from lighting and projection optics for modern vehicles to home or street lighting using LED technology. Glass is the material of choice for most of those application fields. It has several advantages over polymers, including heat and scratch resistance as well as longevity and recyclability. Non-isothermal glass molding has become a viable hot forming technology for mass production of optics. The major challenge is enabling a scalable replication process allowing the optical glass elements to be manufactured with high form accuracy and at low-cost production with low reject rates. This work introduces recent developments in glass optics manufacturing that allow the fulfilment of seemingly contradicting criteria: the economic growth and the need for less consumption of resources and energy. While single cavity non-isothermal molding is state-of-the-art, a manufacturing innovation through wafer-scale molding enables an exponentially increasing number of optics to be produced per production shift, allowing a significant reduction of unit costs. In parallel, as multiple optics are produced in one manufacturing cycle, the energy consumption and the consequent CO2 emission can be reduced. In contrast, the technological development arises several challenges that will be discussed in this work. Besides the selection of suitable mold concepts and materials, the challenges also include the temperature control of the mold and the blank up to the optimization of flow and shrinking mechanisms of the glass during rapid forming. Another difficulty in the non-isothermal glass molding is to maintain the low form deviation required for precision optics, repeatability, and low failure rates through process optimization. Finally, detail calculations of cost, energy and CO2 consumption, in comparison with conventional fabrication of glass components using grinding and polishing as well as single cavity molding, will be demonstrated. The non-isothermal wafer-level glass molding is a new technological solution for the sustainable manufacturing of optics at large-scaled production.

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Section: Fig 3 Process Chain Of the Rod Pressing Processmentioning

confidence: 99%

“…The forming, cooling, and fine cooling phases are similar to the rod pressing process. Finally, the glass is separated by cutting processes [1,12,13].…”

Section: Fig 3 Process Chain Of the Rod Pressing Processmentioning

confidence: 99%