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摘要:
为满足光学行业的市场需求，非球面光学元件的快速制造技术是实现低成本、批量化、高精度生产的最佳解决方案之一。本文主要介绍了非球面光学元件的快速制造技术，包括精密光学玻璃模压成型技术和精密光学塑料注射成型技术，并对两种技术与其他非球面光学元件的制造技术进行了对比，阐述了模具材料种类、模具加工方法、成型材料、成型过程等内容。最后总结了近年来非球面光学元件的快速制造技术的发展现状，并对未来发展进行了展望。
Abstract:In order to meet the market demand of the optical industry, the rapid manufacturing technology of aspheric optical elements is one of the best solutions to realize low cost, mass production, and high precision production. This paper mainly introduces the rapid manufacturing technology of aspheric optical elements, including precision optical glass molding technology and precision optical plastic injection molding technology, and compares the two technologies with the manufacturing technology of other aspheric optical elements. This paper also expounds on the types of mold materials, mold processing methods, molding materials, molding process, etc. Finally, the development status of rapid manufacturing technology of aspheric optical elements in recent years is summarized, and future development has prospected.
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Overview: Aspheric optical elements are widely used in various optical systems because they can eliminate spherical aberration, coma, astigmatism, field distortion, and other unfavorable factors. This type of lens can also reduce the loss of light energy and obtain high-quality images and optical properties. With the rapid development of the optical industry, the demand for aspheric optical elements is also increasing. At the same time, the optical components in the system need to ensure high surface accuracy and low optical birefringence to improve the user experience, which puts forward higher requirements and challenges for the manufacturing method of optical components. The traditional manufacturing methods of aspheric optical elements often have problems such as high manufacturing costs, long processing cycles, and difficulty in ensuring manufacturing accuracy, which limits the wide application of aspheric optical elements. In order to overcome these constraints, researchers have conducted in-depth research on the manufacturing technology of aspheric optical components, aiming to achieve efficient, economical, and accurate manufacturing methods. With the development and popularization of computers in recent years, advanced optical manufacturing technology has gradually begun to be applied to the processing of optical components, and is gradually replacing traditional processing techniques such as classical polishing that have been used for decades. It includes ultra-precision cutting technology, ultra-precision grinding technology, ultra-precision polishing technology, precision glass molding technology, and precision injection molding technology. This paper first introduces the advanced optical manufacturing technology of various aspheric optical components and compares them horizontally. Among them, ultra-precision cutting technology, ultra-precision grinding technology, and ultra-precision polishing technology have high precision of machining components. However, due to the high precision of machining components, ultra-precision machining technology usually requires a slower feed rate, so the machining speed is relatively slow, which leads to the increased manufacturing cost of components. In order to meet the market demand, the rapid manufacturing technology of aspheric optical components is one of the best solutions to achieve low-cost, high-volume, and high-precision production. Then we introduce the precision glass molding technology and precision injection molding technology in detail. The two technologies are compared with the manufacturing technology of other aspheric optical components, and the types of mold materials, mold processing methods, molding materials, molding process and so on are described. Finally, the development status of rapid manufacturing technology of aspheric optical elements in recent years is summarized, and the future development is prospected.
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图 1 非球面光学元件的制造工艺链
Figure 1. Process chains for manufacturing aspheric optical elements
图 2 PGM原理图。(a)加热阶段；(b)加压阶段；(c)退火阶段；(d)冷却阶段
Figure 2. PGM schematic diagram. (a) Heating stage; (b) Pressurizing stage; (c) Annealing stage; (d) Cooling stage
图 15 硫系玻璃与镀有Re–Ir的模具表面粘附[42]。(a)模压成型前的模具表面；(b) 330 ℃模压成型后的模具表面；(C) 340 ℃模压成型后的模具表面
Figure 15. Adhesion of sulfide glass to the surface of a mold coated with Re-Ir[42]. (a) Mold surface before molding; (b) The surface of the mold after molding at 330 ℃ ; (C) The surface of the mold after molding at 340 ℃
图 23 注塑成型工艺原理。(a) 塑化阶段；(b) 注射阶段；(c) 保压阶段；(d)冷却阶段；(e)开模脱模
Figure 23. Principle of injection molding process. (a) Plasticizing stage; (b) Injection stage; (c) Holding stage; (d) Cooling stage; (e) Mold opening and unmolding
图 30 光学元件的残余应力和双折射分布[74]。(a) PC光学元件最大残余应力的仿真与实验数据比较； (b)光学元件的残余应力分布模拟和实验对比
Figure 30. Residual stress and birefringence distribution of optical components[74]. (a) Simulation and comparison of maximum residual stress of PC optics; (b) Simulation and experimental comparison of residual stress distribution of optical components
图 32 仿真模型的限流器设计及短射实验[77]。(a)限流器尺寸参数；(b) 带限流器的流道；(c) 原始流道的速度场图；(d) 带限流器的流道的速度场图；(e)短射模拟仿真；(f)短射实验结果
Figure 32. Simulation model current limiter design and short-shot experiment [77]. (a) Dimensional parameters of restrictor; (b) Runner with restrictor for 4-cavity mold; (c) Velocity field plot for original runner; (d) Velocity field plot for runner with restrictor; (e) Short-shot simulation; (f) Results of short-shot experiments
图 34 在模具上加工高精度自由曲面的迭代循环细节[79]。(a)迭代循环前的曲面偏差，三维视图；(b)迭代循环前的曲面偏差，俯视图；(c)拟合的傅里叶函数作为曲面偏差的误差描述；(d)拟合的偏差和发现的数学描述之间的误差；(e)一个迭代循环后的曲面偏差，三维视图；(f)一个迭代循环后的曲面偏差，俯视图
Figure 34. Details of the iteration loop for machining a high precision freeform surface on the mold[79]. (a) Surface deviation before iteration loop, 3D view; (b) Surface deviation before iteration loop, top view; (c) Fitted Fourier function as error description of the surface deviation; (d) Error between fitted deviation and found mathematical description; (e) Surface deviation after one iteration loop, 3D view; (f) Surface deviation after one iteration loop, top view
表 1 单个非球面光学元件的不同制造技术对比
Table 1. Comparison of manufacturing techniques of aspherical optical elements
精磨玻璃模压技术 精密注塑成型技术 超精密切削技术 超精密磨削技术 超精密抛光技术 加工周期 70 s~150 s 15 s~75 s 1000 s以上 1000 s以上 3000 s以上 加工精度 1 μm 3 μm 0.5 μm以下 0.5 μm以下 0.1 μm以下 
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表 2 精密模压成型技术加工元件种类
Table 2. Precision glass molding technology processing components
非球面透镜 超细内窥镜的物镜 非球面微透镜阵列 非球面柱面镜片 非球面柱面镜阵列 外观尺寸 Φ1 mm~Φ30 mm Φ0.35 mm Φ7 mm以下 5 mm×15 mm 8 mm×8 mm 中心厚度 0.5 mm~20 mm 0.2 mm~5 mm 0.3 mm以上 3 mm 0.7 mm 形状精度 0.5 μm 1 μm以下 1 μm以下 1 μm 1 μm
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表 3 精密注塑成型技术加工元件种类
Table 3. Precision injection molding technology processing components
非球面透镜 非球面衍射元件 非球面微透镜阵列 外观尺寸 Φ1 mm~Φ50 mm Φ0.35 mm Φ7 mm以下 中心厚度 0.5 mm~20 mm 0.2 mm~5 mm 0.3 mm以上 形状精度 3 μm 5 μm以下 5 μm以下
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