Process Chain for the Replication of Complex Optical Glass Components

Precision glass molding is becoming a promising technology for fast production of complex optical glass components in high volume. It is a replication process and becomes economical after a few batches. The glass molding process can be holistically described by a process chain which starts with the design of the optical component and modeling of the glass molding process using numerical simulation. An ultraprecision grinding process is applied to manufacturing the molds. Chemically insert coatings are necessary in order to prolong mold life because the mold has to withstand high mechanical and thermal loads. The parameters of the subsequent molding steps such as temperature or pressure depend on the type of glass and the size of the optical component. The last step of the process chain is the qualification of the optical components by measuring their optical properties using precision metrology.