Ever wondered how advanced optical devices, like night-vision goggles and AR displays, get their complex lens designs? It’s all thanks to combining computer numerical control (CNC) machining and injection molding. THY Precision has perfected this blend for top-notch results. But what makes this combo so special, and how does it make complex optical lenses?
Key Takeaways
- THY Precision Injection molding optical lenses makes complex optical lens designs affordable to produce.
- Mechanical mounting fiducials can be added right into the molded lens, making assembly easier.
- Polymer optics are much lighter than traditional glass lenses.
- THY Precision’s skill in CNC and injection molding optical lensesmeans precise, quality optical parts.
- These two methods together open up new possibilities for advanced optical systems.
The Advantages of Injection Molded Polymerjectionmoulding OpticsCost-Effective Process
Producing optical lenses with injection molding optical lenses has many benefits over traditional glass methods. Injection molding optical lensesuses thermoplastics that are cheaper than glass. It also allows for making lots of lenses at a low cost.
The injection moulding process step by step cuts down on material and production costs. Thermoplastics are cheaper than glass and can be easily melted and molded. The process is faster than making glass optics, which also lowers costs.
Economies of Scale for Plastic Injection Molding
Being able to make molds with many cavities is a big plus. This lets them make many polymer optics at once. This method, called economies of scale, makes each lens cheaper for large orders. The cost-effective nature of injection molding optical lenses is great for many uses, from gadgets to medical tools.
Adding aspheric surfaces to lenses is easy with injection molding. This helps fix lens problems and make complex shapes accurately. This makes plastic injection molding optical lenses even more cost-effective for optics.
“The injection molding optical lenses cycle time is much shorter than the grinding and polishing techniques used to produce glass optics, and multi-cavity molds can be built to produce multiple lenses during each molding cycle, further reducing costs for high-volume programs with commercial tolerances.”
Mechanical Properties of Injection Molded Polymer Optics
When making injection molding optical lenses of polymer optics, it’s key to know the materials’ mechanical properties. The coefficient of thermal expansion for these plastics is much higher than glass. This is crucial for designing optics that work well over a wide temperature range.
Optical thermoplastics have a low glass transition temperature. For example, polystyrene and acrylic start to soften around 80-90°C. Polycarbonates and some other plastics can get up to 130°C before they start to soften. This affects how hot the polymer optics can safely be.
Optical Properties Considerations
The optical properties of injection molded polymer optics are also vital. Most thermoplastics absorb water, which can change their size. This is something to think about when making optics that need to be precise.
Polymers are often lighter than glass and can handle more impact. This makes them a good choice for some uses.
| Property | Value |
|---|---|
| Thermal Expansion | About 1 order of magnitude more than glass |
| Glass Transition Temperature | 80-90°C for polystyrene and acrylic, 130°C for polycarbonates and some polyesters |
| Water Absorption | Most thermoplastics (except COP and COC) absorb water, leading to size changes |
| Weight | Polymers are lighter than glass for the same volume |
| Impact Resistance | Polymers can withstand more impact than glass |
Knowing the mechanical and optical properties of injection molded polymer optics helps designers make smart choices. They can create optics that meet their application’s needs.
injectionmoulding process step by step Precision Injection Molding
At THY Precision, we know how crucial precision is in making top-notch polymer optics. Our molds have three main parts: the cavity details, optical inserts, and a housing that keeps everything in place.
Polymer optics are great because they can have both optical and mechanical parts in one. The mold is made to be the exact opposite of the final product. When the thermoplastics cool, they shrink a bit, around 0.5-0.6%. The machine used for injection molding optical lenses has a fixed and moving platen, a clamping unit, and an injection unit.
The process starts with putting plastic pellets into the injection unit. They get melted and then pushed into the mold. As it cools, the polymer takes the shape of the mold, making the optic we want.
| Key Steps of the Precision Injection Molding Process |
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By getting the injectionmoulding process right, THY Precision can make polymer optics that are precise and meet high standards. Our skills in injectionmolding and optical engineering mean we always get great results.
Measuring and Verifying Aspheric Optics
Getting the right measurements of aspheric optics is key for good design and making them work well. THY Precision leads in making precise parts with injection molding. They know how hard it is to measure these complex shapes.
The aspheric optics surface is like a mix of spheres with changing sizes. This makes it hard to measure with old methods like interferometry and profilometry. Before, CGH and null lenses were used, but they were hard to set up and expensive.
Simplified Aspheric Measurement with the VFA+ System
THY Precision has found a better way with the VFA+ System. This new method uses phase-shifting interferometry and displacement measuring interferometry (DMI). It makes measuring aspheric optics easier and more reliable.
- The VFA+ System makes measuring aspheric optics simpler, cutting down on cost and complexity.
- It combines interferometry and profilometry to make sure the asphere matches the design and is good for making parts.
- This system lets THY Precision make top-quality aspheric optics that meet their customers’ high standards.
| Measurement Technique | Advantages | Limitations |
|---|---|---|
| Interferometry | Compares a reference wavefront to the test part to get surface figure data | Hard with aspheres because of their complex shapes |
| Profilometry | Directly measures the surface profile | May miss some surface details |
| VFA+ System | Uses phase-shifting interferometry and DMI for easy and reliable aspheric optics measurement | Needs special gear and knowledge |
With the VFA+ System, THY Precision makes sure their aspheric optics are top-notch and work well. This lets them offer innovative and dependable solutions to their clients.
“The VFA+ System has changed the game for us in measuring and checking our aspheric optics. It’s made the process easier, cheaper, and given us the confidence to deliver great products to our clients.”
– THY Precision Engineer
Conclusion
CNC machining and injection molding have changed how we make complex optical lenses. THY Precision uses these technologies together to make high-quality polymer optics at a lower cost. This process lets them add both mechanical and optical features into one piece.
THY Precision’s polymer optics beat traditional glass in many ways. They are cheaper to make and can have complex shapes with great precision. Knowing how these materials work is key to making great optical lenses. THY Precision knows this well, making sure their lenses work perfectly.
With precision injection molding and advanced checks, THY Precision makes sure their optics are top-notch. They work closely with customers to bring out the best in polymer optics. This helps you push the limits of what optical lenses can do.