Tolerance verification of precision injection moulded Fresnel lenses

Loaldi, Dario; Calaon, Matteo; Quagliotti, Danilo; Parenti, Paolo; Annoni, Massimiliano; Tosello, Guido

doi:10.1016/j.procir.2018.05.004

Cited by 10 publications

(10 citation statements)

References 8 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The component under investigation is the aspheric-corrected square Fresnel lens shown in Figure 2. Tolerance specifications are allocated to surface groove peak-to-valley (PV), as presented in a previous study [46]. The materials employed for the experimentation were a cyclo-olefin polymer (COP) commercially available under the trade name Zeonex ® E48R, produced by Zeon© company, Tokyo, Japan, and a polymethyl methacrylate (PMMA), traded under Altuglas ® V825T, produced by Arkema©, Colombes, France.…”

Section: Methodsmentioning

confidence: 99%

“…The overall expanded uncertainty related to measurements was guided by ISO 15530-3:2011 [47] and ISO 14253-2:2007 [48]. The individual uncertainty contributors are reported in Table 2 for step height, and in Table 3 for pitch measurements, and they were calculated as described in a previous study [46]. The traceability was established through calibrated gauge blocks.…”

Section: Methodsmentioning

confidence: 99%

See 1 more Smart Citation

Manufacturing Signatures of Injection Molding and Injection Compression Molding for Micro-Structured Polymer Fresnel Lens Production

et al. 2018

Self Cite

View full text Add to dashboard Cite

Injection compression molding (ICM) provides enhanced optical performances of molded polymer optics in terms of birefringence and transmission of light compared to Injection molding (IM). Nevertheless, ICM requires case-dedicated process optimization to ensure that the required high accuracy geometrical replication is achieved, particularly especially in the case of surface micro-features. In this study, two factorial designs of experiments (DOE) were carried out to investigate the replication capability of IM and ICM on a micro structured Fresnel lens. A laser scanning confocal microscope was employed for the quality control of the optical components. Thus, a detailed uncertainty budget was established for the dimensional measurements of the replicated Fresnel lenses, considering specifically peak-to-valley (PV) step height and the pitch of the grooves. Additional monitoring of injection pressure allowed for the definition of a manufacturing signature, namely, the process fingerprint for the evaluation of the replication fidelity under different process conditions. Moreover, considerations on the warpage of parts were related to a manufacturing signature of the molding processes. At last, the global part mass average and standard deviation were measured to correlate local geometrical replication performances with global part quality trends.

show abstract

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Manufacturing Signatures of Injection Molding and Injection Compression Molding for Micro-Structured Polymer Fresnel Lens Production

et al. 2018

Self Cite

View full text Add to dashboard Cite

show abstract

“…Kwak et al [53] applied neural network technology to the field of computer simulation to improve the surface dimensional accuracy of optical components under injection molding processing, and conducted experiments to verify the correctness of the computer simulation results. Loaldi et al [54] used a method of checking Fresnel surface microstructure and process, a detailed evaluation of uncertain factors, effectively establishing the correlation between microstructures, improving the overall optical performance of the Fresnel lens. Bickerton and Abdullah [55] studied the injection stage of injection compression molding, and found that the injection (a) Milling process (b) Turning process Fig.…”

Section: Multi-materials Injection Moldingmentioning

confidence: 99%

Overview of Injection Molding Technology for Processing Polymers and Their Composites

Fu¹,

Xu²,

Liu³

et al. 2020

ES Mater.Manuf.

View full text Add to dashboard Cite

Injection molding technology has been in development for almost 150 years. Injection molding is a molding technology that melts the material with the aid of a screw and an external heating device and then injects it into a mold to form the corresponding product as the mold cools. At present, many types of materials can be used to mold products by injection molding. Many requirements and problems in the processing of different materials have also caursed the birth of many molding processes. At present, injection molding has been applied in many fields, from daily necessities that are closely related to our lives to parts and components in the aerospace field. At present, injection molding still faces the challenges of processing new materials, and the continuous improvement of the existing equipment technology is required for the continuous development of injection molding.

show abstract

“…Many publications described the use of injection moulding (IM) and injection compression moulding (ICM) in the mass production of optical elements, especially for manufacturing high precision lenses at micro/nano scales, with advantages of better nano surface finishing, higher geometrical replication fidelity and mass production capability. However, the use of IM for initial lens prototyping is extensively pricy [9][10][11][12][13][14].…”

Section: Introductionmentioning

confidence: 99%

Investigation of non-imaging Fresnel lens prototyping with different manufacturing methods for solar energy application

Sexton

Qandil

Abdallah

et al. 2021

Journal of Mechanical and Energy Engineering

View full text Add to dashboard Cite

Non-imaging Fresnel lenses have been playing an important role in improving the efficiency of the solar energy systems. Many researchers have been developing novel designs of Fresnel lenses to enhance the concentrator performance. To bring the complex design of a Fresnel lens from a conceptual theory to a real-life application while maintaining its efficiency, it is critical to find the optimum manufacturing method that achieves the best quality fabrication at low cost in the lab scale. This work will systematically investigate four advanced manufacturing methods for their lens-making capabilities, including pressure casting, hot embossing, 3D printing, and CNC machining. Six Fresnel lenses were fabricated by the four methods, which were tested in the lab by a solar simulator and a solar cell to demonstrate their performances. The CNC machining provides the best quality lab-scale Fresnel lens that enhances the solar cell efficiency by 118.3%. 3D printing and hot embossing methods are also promising for the fabrication of good performance lenses – increasing the solar cell efficiency by 40-70%. However, the 3D printed lens has the issue of material degradation on the long term. Although the pressure casting is the easiest manufacturing method, the performance of fabricated lens was the lowest.

show abstract

Tolerance verification of precision injection moulded Fresnel lenses

Cited by 10 publications

References 8 publications

Manufacturing Signatures of Injection Molding and Injection Compression Molding for Micro-Structured Polymer Fresnel Lens Production

Manufacturing Signatures of Injection Molding and Injection Compression Molding for Micro-Structured Polymer Fresnel Lens Production

Overview of Injection Molding Technology for Processing Polymers and Their Composites

Investigation of non-imaging Fresnel lens prototyping with different manufacturing methods for solar energy application

Contact Info

Product

Resources

About