High Precision Freeform Polymer Optics

Abstract

Injection molding offers a cost efficient method for manufacturing high precision plastic optics for high volume applications. Beside classical optical surfaces like planes, spheres and also aspheres the demand for surfaces without symmetric properties, so called freeform surfaces, continues to rise. To push the surface accuracy for high volume applications for the molded freeform lens, new 3D iteration cycles to compensate systematically residual errors have to be developed. This paper will illustrate a new way for the manufacturing of ultra precision mold tool inserts with submicron precision and show the manufacturing of replicated freeform surfaces with micrometer range shape accuracy at diameters up to 40 mm. Furthermore, two examples for molded, energy and material efficient freeform optics adapted to the green photonics philosophy are shown and explained.