Tech Briefs Magazine - May 2021 - PIT-22

between supplier and product developer is vital.

Plastic vs Glass

Micro-optics are typically tiny lenses, beam-splitters, prisms, light-pipes, and other optical components
in the range of 20 microns to 1 mm in size.

Injection molding is now a viable manufacturing technology to use for mass-producing plastic microoptic parts.

optical elements (DOEs) being in the
range of a few hundred nanometers to a
few micrometers. Even refractive micro
lens arrays typically have relief depths of
less than 100 microns. Such flatness
characteristics have opened up the use
of production technologies such as

injection molding, which offer significant cost advantages as component volume increases. Use of injection molding
for micro-optic manufacture, however,
requires the optimization of design,
mastering, tooling, and production
steps, meaning a close interaction

Superimposed upon the recent history of micro-optics is the increased popularity of plastic as a manufacturing material rather than glass. As the market
expands, and the demand for modern
optical applications increases, polymerbased injection molded optics are now
found in a broad range of products.
Today micro-optic fabrication is split
in two: the supply of key components in
low volume for laser, telecom, medical
and metrology applications; and the supply of high volume and low-cost microoptics for the consumer market. Key
drivers behind both areas has been the
increasing sophistication of micro-injection molding technologies, as well as
dramatic developments in materials,
which means that today, complex, miniature, and previously fragile micro-optics
are now robust, and can withstand even
the harsh environmental requirements
of the consumer electronic industry
including infrared (IR) reflow and thermal shock. Working in plastic also introduces enormous design freedom.
Injection molding is the only viable
manufacturing technology to use when
low-cost, high-volume production runs
are required. A single tool is capable of
mass-producing plastic micro-optic parts
(including necessary surface finish), and
if process controls are rigorous enough,
100% accurate replication is possible
run after run. This is not the case when
manufacturing in glass.
In addition, mounting and mechanical features such as spacers and flanges
can be integrated into plastic optical
components, thereby removing the
need for additional components and
assembly considerations. Unique cosmetic, functional filter, and other properties can also be added to enhance or
improve the properties of the raw molding polymer, which again cannot be
done with glass.

Partner Choice
The overall micro-optic manufacturing sector is characterized by high costs
and high risks, with few qualified and
reliable manufacturers available that can
manufacture to the level of accuracy
required, in the timeframe required,
and at a sensible and competitive cost.
Like all niche micro manufacturing sectors, it is especially vital in the area of
Photonics & Imaging Technology, May 2021

Cov

ToC

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Tech Briefs Magazine - May 2021

Table of Contents for the Digital Edition of Tech Briefs Magazine - May 2021