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Zeng Z, Zhou T, Yu Q, Zhou J, Wang G, Xie Q, Wang Z, Yao X, Guo Y. Alignment error modeling and control of a double-sided microlens array during precision glass molding. Microsyst Nanoeng 2024; 10:48. [PMID: 38590817 PMCID: PMC10999453 DOI: 10.1038/s41378-024-00668-7] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 10/09/2023] [Revised: 01/11/2024] [Accepted: 01/22/2024] [Indexed: 04/10/2024]
Abstract
Double-sided microlens arrays (DSMLAs) include combinations of two single-sided MLAs to overcome positioning errors and greatly improve light transmissivity compared to other types of lenses. Precision glass molding (PGM) is used to fabricate DSMLAs, but controlling alignment errors during this process is challenging. In this paper, a mold assembly was manufactured with a novel combination of materials to improve the alignment accuracy of mold cores during PGM by using the nonlinear thermal expansion characteristics of the various materials to improve the DSMLA alignment accuracy. By establishing a mathematical model of the DSMLA alignment error and a thermal expansion model of the mold-sleeve pair, the relationship between the maximum alignment error of the DSMLA and the mold-sleeve gap was determined. This research provides a method to optimize the mold-sleeve gap and minimize the alignment error of the DSMLA. The measured DSMLA alignment error was 10.56 μm, which is similar to the predicted maximum alignment error. Optical measurements showed that the uniformity of the homogenized beam spot was 97.81%, and the effective homogeneous area accounted for 91.66% of the total area. This proposed method provides a novel strategy to improve the performance of DSMLAs.
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Affiliation(s)
- Zihao Zeng
- School of Medical Technology, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Tianfeng Zhou
- School of Medical Technology, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Qian Yu
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Jia Zhou
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Gang Wang
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Qiuchen Xie
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Zifan Wang
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Xiaoqiang Yao
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
| | - Yubing Guo
- School of Medical Technology, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081 China
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