The latest development of sophisticated high-precision optical devices necessitates precision fabrication methodologies of freeform microlens having very tight, up to micron tolerance. Instead of adopting high-end multi-axis freeform machining approach, the proposed acrylic multi-surfaced microaspheric lens, with the axial diameter of 1.3mm, was cost-effectively prototyped and fabricated by single point diamond turning and micro-injection molding technology respectively. The micro-optical component was used as an opto-electronic module for high-speed data-transmission in fiber optics. Sequential fixturing technique was applied to facilitate the precise fabrication of the optical surfaces from different optical alignments. The aspherical accuracy and surface finish of the machined surfaces were evaluated, and end result was determined to be satisfactory. Further, the ultra precision tooling would be developed for micro-injection molding for carrying out mass production of the micro-optical component.
Magneto-rheological-finishing (MRF) technology is capable of substantially improving the surface figure of spherical lens to about 1/20 wavelength. Nonetheless, since MRF technology is an ultra-fine polishing process, in which only less than a few microns of material will be removed per cycle, time for making an aspheric surface from a best-fit sphere can be very significant. The situation can be worse if the surface profile is considerably deviated from its best-fit spherical surface. This is not desirable for actual production, and thus a manufacturing cell is proposed to enhance the efficiency of the high precision lens manufacturing process. On the other hand, MRF was suggested to be an alternative for lapping of surface of ceramic lens mould insert. Rather than using the abrasive particles in typical lapping process, the magnetized slurry in MRF is moved past the rotating surface of mould insert locally under the computer-control process so as to achieve the desired surface form accuracy.
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