Fabrication of Aspheric Micro Lens Array by Slow Tool Servo

2009 ◽  
Vol 76-78 ◽  
pp. 479-484 ◽  
Author(s):  
Chun Chieh Chen ◽  
Choung Lii Chao ◽  
Wei Yao Hsu ◽  
Fong Chi Chen ◽  
Chung Woei Chao
Keyword(s):  
Tool Path ◽  
Diamond Turning ◽  
Lens Array ◽  
Fast Development ◽  
Ultra Precision ◽  
Slow Tool Servo ◽  
Micro Lens Array ◽  
Array Fabrication ◽  
Micro Lens ◽  
Better Than

Owing to the fast development in photonic, telecommunication, and opto-electronic industries, the demand for various micro-lens arrays is rapidly growing. The slow tool servo technique was applied on an ultra-precision diamond turning machine in the present research in conjunction with the tool path generating algorithm for aspheric micro-lens array fabrication. An aspheric lens array of 100% filling factor was successfully produced and the form accuracy and surface roughness were better than 0.15μm and 3nm for all the obtained lenses.

Ultra Precision Diamond Shaping of an Elliptical Micro-Lens Array

2009 ◽  
Vol 407-408 ◽  
pp. 380-383
Author(s):  
Choung Lii Chao ◽  
Chun Chieh Chen ◽  
Wen Chen Chou
Keyword(s):  
Filling Factor ◽  
Flat Panel Display ◽  
Flat Panel ◽  
Lens Array ◽  
Display Devices ◽  
High Filling Factor ◽  
Ultra Precision ◽  
Micro Lens Array ◽  
Micro Lens ◽  
Better Than

Micro lens array is widely used in photonics and telecommunication products, including back-light module of flat panel display devices and white-light LED illumination. The ultra precision diamond shaping method together with tool servo technique was studied and developed in this research to generate elliptical micro lens array. Each elliptical micro lens has radii in X and Y direction of 1.0 mm and 1.5 mm respectively. A high filling-factor (100 %) elliptical micro lens array with form accuracy better than 0.15μm and surface roughness around 5nm Ra was successfully fabricated.

Factors affecting the machining precision of a micro-lens array on a spherical surface in slow tool servo machining

2018 ◽  
Vol 26 (10) ◽  
pp. 2516-2526
Author(s):  
孙 豪 SUN Hao ◽  
起建立 QI Jian-li ◽  
林泽钦 LIN Ze-qin ◽  
王素娟 WANG Su-juan ◽  
颜志涛 YAN Zhi-tao
Keyword(s):  
Spherical Surface ◽  
Lens Array ◽  
Factors Affecting ◽  
Machining Precision ◽  
Slow Tool Servo ◽  
Micro Lens Array ◽  
Micro Lens

Random micro-lens array illumination device manufactured by ultra-precision machining

2014 ◽  
Author(s):  
Yukinobu Nishio ◽  
Kayoko Fujimura ◽  
Sho Ogihara ◽  
Masato Okano ◽  
Seiichiro Kitagawa
Keyword(s):  
Precision Machining ◽  
Lens Array ◽  
Ultra Precision ◽  
Micro Lens Array ◽  
Array Illumination ◽  
Micro Lens

A Study of Tool Path Generation for Machining of Precision Roller with Wavy Patterned Microstructures by Slow Tool Servo

2016 ◽  
Vol 679 ◽  
pp. 191-197
Author(s):  
Ling Bao Kong ◽  
Chi Fai Cheung ◽  
Wing Bun Lee ◽  
Suet To ◽  
Su Juan Wang ◽  
...  
Keyword(s):  
Tool Path ◽  
Single Point ◽  
Research Work ◽  
Axial Direction ◽  
Diamond Turning ◽  
Machining Process ◽  
Fast Tool Servo ◽  
Roller Surface ◽  
Ultra Precision ◽  
Slow Tool Servo

Embossing by patterned rollers is one of the most efficient machining approaches for manufacturing plastic films with patterned microstructures, and the precision roller with patterned microstructures is the key tooling component in the roll-to-roll process. Single-point diamond turning with a slow or fast tool servo is an enabling and efficient ultra-precision machining process to fabricate microstructures through a simple process to achieve optical surface finish directly. Most of the current studies on slow or fast tool servo machining processes either focus on face machining of patterned microstructures, or on tool servo machining of microstructures in the radial direction of precision rollers. Relatively little research work is found in relation to machining patterned microstructures on a precision roller by using the tool servo in the axial direction. This paper presents a pilot study on the development of a tool path generator for machining precision rollers with wavy patterned microstructures by using slow tool servo machining in the axial direction on a precision roller. The machining mechanism is firstly explained, based on which the tool path generator is developed for machining wavy patterned microstructures on a precision roller surface. Preliminary experimental work was conducted to study the generation of wavy patterned microstructures on a precision roller using a four-axis ultra-precision machine. The machined wavy microstructures on the roller surface are measured and analyzed to successfully validate the performance of the proposed tool path generator.

A Novel Method for Profile Error Analysis of Freeform Surfaces in FTS/STS Diamond Turning

2014 ◽  
Vol 625 ◽  
pp. 101-107
Author(s):  
Wee Keong Neo ◽  
Mark Derek Nadhan ◽  
A. Senthil Kumar ◽  
Mustafizur Rahman
Keyword(s):  
Error Analysis ◽  
Tool Path ◽  
Diamond Turning ◽  
Profile Error ◽  
Nose Radius ◽  
Freeform Surfaces ◽  
Slow Tool Servo ◽  
Optics Industry ◽  
Micro Lens Array ◽  
And Control

Fast/slow tool servo (FTS/STS) technology plays an important role in machining freeform surfaces for the modern optics industry. The accuracies of these surfaces not only depend on the performance of the FTS/STS but also on the methods of tool path generation (TPG). Current methods of pre-compensating tool nose radius and control dynamics still do not address the inherent profile errors arise from the methods of TPG. Furthermore, it is also not efficient to characterize a freeform surface in the post-machining stage, giving a high risk of failing to meet the accuracy requirements. In this paper, a profile error analysis (PEA) is introduced into the pre-machining stage to address this inherent profile error. PEA is carried out to compare two methods of TPG, namely the constant angle and constant arc methods and optimizes the number of cutting points in the TPG. Thus, the profile accuracy can be pre-determined to meet accuracy requirements by determining the appropriate TPG method with a least number of the cutting points. In the experiments, sinusoidal wave grid and micro-lens array surfaces are fabricated and their profiles successfully achieve the accuracy tolerance of 1 μm. These further credit the capability of PEA as an effective and accurate tool in improving profile accuracies and meeting accuracy requirements.

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