Doctor of Philosophy, The Ohio State University, 2021, Industrial and Systems Engineering
Applications of precise optical components with complex shapes are becoming more popular because of demands for more accurate, smaller size optical components. Although fabrication techniques of the components have advanced in recent years, only molding based methods are typically suitable for mass production. On the other hand, molding based methods are less capable of creating complex optical components. To deal with these limitations, a process based on nickel electroforming is introduced to replicate mold inserts directly from a plastic optical component, which itself can be fabricated by any fabrication methods with high flexibility. Then, using the plated mold insert in precision compression molding, the optical components are replicated.
To investigate replication capabilities of the developed method in fabrication of plastic optical components, a polymethylmethacrylate (PMMA) microlens array was replicated to a nickel-plated mold first from another plastic microlens array then mass-produced using compression molding process. Properties of both microlens arrays, were investigated for geometrical accuracy, surface quality, and optical performance. The results demonstrated a promising technique to manufacture plastic optical component with high production rates.
Fabrication capabilities of the method in production of infrared optics was also evaluated through producing an infrared microlens array from a plastic microlens array. Comparison between the fabricated infrared microlens array and the plastic microlens array in terms of geometry, surface quality, and optical performance has shown that it is a promising technique for replicating infrared microlens arrays.
Using the developed method, a new fabrication method of non-planar optical component with large area was also proposed and demonstrated by producing micro feature on a cylindrical surface. The technique was capable to transfer micro-optical features from a planar surface, which is much easier to pro (open full item for complete abstract)
Committee: Allen Yi (Advisor); Jose Castro (Committee Member); Yannis Korkolis (Committee Member)
Subjects: Engineering; Industrial Engineering; Mechanical Engineering; Optics; Plastics