Machining of Lenticular Lens Silicon Molds with a Combination of Laser Ablation and Diamond Cutting

Study of the Transcription Effects of Pressing Dies with Ultrasonic Polishing on Glass Molding

The micro lens array (MLA) has played an important role in optical systems for the past few years, and the precision of pressing dies has dominated the quality of MLAs in glass molding. Few studies have covered the transcription effects on surface roughness of pressing dies for this technology. Therefore, this research utilized pressing dies to produce a sine-wave lens array on glass molding, to transform the Gauss-distributed spotlight into a uniform straight one and then characterize the transcription effects of these lenses. Pressing dies with a sine-wave shape were firstly cut by wire electrical discharge machining (WEDM), and then ultrasonic polishing using diamond abrasives was applied to finish the sine-wave surface with an original roughness of 0.2 μm Ra. Next, the sine-wave lens arrays were pressed by glass molding at the appropriate pressure and temperature, before evaluating the transcription effects of transforming the Gauss-distributed spotlight into a uniform straight one. The result showed that the sine-wave lens array stuck easily to the pressing die and then ruptured during glass molding due to the poor surface roughness of pressing tool. However, the diamond abrasive with appropriate sizes could establish good surface roughness on pressing dies via ultrasonic polishing, and the pressing die with a low surface roughness of 0.08 μm Ra was able to successfully perform MLA in the glass molding. However, only pressing dies with a surface roughness smaller than 0.023 μm Ra could produce precision glass lenses to transform the Gauss-distributed spotlight into a uniform straight one.

3D Printed Contact Lenses

Although the manufacturing processes of contact lenses are well established, the use of additive manufacturing for their fabrication opens many new possibilities to explore. The current study demonstrates the fabrication of personalized smart contract lenses utilizing additive manufacturing. The study includes 3-dimensional (3D) modeling of contact lenses with the assistance of a computer aided designing tool based on standard commercial contact lens dimension, followed by the selection of the suitable materials and 3D printing of contact lenses. The 3D printing parameters were optimized to achieve the desired lens geometries, and a post processing treatment was performed to achieve a smooth surface finish. The study also presents functionalized contact lenses with built-in sensing abilities by utilizing microchannels at the contact lens edges. Tinted contact lenses were printed and nanopatterns were textured onto the contact lens surfaces through holographic laser ablation. 3D printed contact lenses have advantages over conventional contact lenses, offering customized ophthalmic devices and the capability to integrate with optical sensors for diagnostics.