Precision replication of microlens arrays using variotherm-assisted microinjection moulding

Abstract

Injection moulding is ubiquitous in the production of plastic optical components, the functionality of which depends on minimising residual stress and on precisely replicating surface forms. In this study, variotherm-assisted microinjection moulding is used to manufacture a practical microlens array designed for light-field applications in order to achieve satisfactory geometric accuracy, surface quality and stress birefringence of the microlenses, all of which are difficult to achieve by conventional microinjection moulding. Based on in-line process monitoring and a comprehensive evaluation regarding the quantitative and qualitative aspects of the aforementioned factors, the replication is shown to correlate well with machine settings and dynamic machine responses. Screw movements are found to be crucial in the replication process. Compared to an optimised conventional microinjection moulding condition, the general residual stress level and uniformity of the microlens array area are improved by 5.08% and 88.11%, respectively, when the warm circuit temperature is 135 °C and enhanced by 2.73% and 84.32%, respectively, by a delayed switch from the warm circuit to the cold circuit. It is concluded that variotherm-assisted microinjection moulding can significantly reduce residual stresses while maintaining excellent geometric accuracy and surface quality.