Generally, optical multilayer coatings are formed on the optical surface for the purpose of anti-reflection. However, these coatings have problems of environmental resistance such that cracks or peelings.
Lately, a technique for realizing an anti-reflection function by forming a sub-wavelength scale structure on the optical surface has been widely studied [1] [2] [3] [4] [5] [6]. Such a structure is called ARS, Anti-Reflective Structure. ARS has excellent environmental resistance compared to multilayer coatings and has the advantage of low dependence on the incidence angle in terms of optical characteristics.
We have studied a method for fabricating ARS using RIE, Reactive Ion Etching. We found that ARS with fine optical properties is formed on the surface of the glass lens by adjusting plasma condition at each etching process. In this report, we will introduce examples of applications to quartz glass. The first case is ARS for the visible light, which achieved a transmittance of 99% or higher. The other is ARS for the deep ultraviolet light. In addition, these ARS have characteristic of water repellency which is useful for optical components.
Generally, an optical lens is reduced its reflection by multilayer anti-reflection coating. However, there are some problems, for example, those coatings cannot be attached for some kind of resins, and show clack or peeling by temperature change or humidity. Lately, anti-reflection effect by sub-wavelength structure on optical lens surface is studied widely. This is called ARS, Anti-Reflective Structure. ARS solved above problems, and has low dependence on incident angle of light. Conventionally, for mass production of ARS lens, we tried injection molding. That is, fabricating fine structure on mold core, and transfer the structure to plastic resin. However, the transferring is very difficult, because of its fineness and adhesion resin to the core. Besides, mold for high transcription is expensive. We tried to fabricate ARS on plastic lens surface by Reactive Ion Etching. Controlling plasma condition at each etching process cleverly, we successfully obtained fine ARS on optical lens surface. The structure has high aspect and narrow pitch which is about 0.1μm, and show good anti-reflective property.
Melt transcription molding is one of novel processes suitable for manufacturing large-area thin film with microstructures.
We designed the mold which enables to transfer structures on both surfaces for the melt transcription molding machine
and examined about relations of temperature and pressure on the accuracy of dimension and optical strain. To keep the
high accuracy of relative position between both surfaces, the mold can avoid strain caused by the thermal expansion of
metal and is optimized by three-dimension unsteady heat conduction analysis. As a result, distribution of pressure mainly
affects stress and distribution density, influences shrinkage and accuracy of position. The decenter between both surfaces
was several micrometers. This makes it possible to mass-produce the large-area optical elements which is formed the
micro and nano structures on both surfaces with extremely low birefringence at high productivity.
This paper describes the fabrication of several diverse examples of molding tools designed for high volume production of plastic and glass optical components. The examples shown demonstrate a wide combination of surface shapes and structures all with nanometer level accuracy. The tungsten carbide molding tools were produced using grinding and magnetorheological finishing (MRF), new raster fabrication, and micro-milling. Mold tools were fabricated to produce a glass free-form surface, (profile accuracy of less than 200nm in PV, surface roughness of less than Ra5nm), a radial arrangement of 188-microlens, a microscopic pin (3um in diameter, 100um in height), and a molding tool for DOE with little optical loss. The molding of glass optics requires mold materials which can be used at high temperatures. In addition to tungsten carbide this paper describes molds fabricated from nano-structural sintered material or ceramic with partially stabilized molecular structure.
Nalux has developed a unique 3D nanometric fabrication technology in several years. Unlike conventional diamond turning machines that are restricted to symmetric components, this device is capable of cutting any free-form surface which can be specified by a xyz coordinate map. This 3D nanometric fabrication technology includes CAD/CAM, ultra-precision machining using single crystal diamond, and high precise shape evaluation. The capabilities of the technology are demonstrated in this paper. We have succeeded in fabricating two unique optical components used in an adaptive optics system at the Subaru 8.2 m Telescope of National Astronomical Observatory of Japan. The first component is a microlens array that is used in the wavefront curvature sensor. This 37- element array has the individual lens elements distributed in a nonrectangular pie pattern, with very tight tolerances on focal point, focal length, lens shape, and the radius of each lens. The second component is an atmospheric phase plate that generates the atmospheric phase aberrations. This component requires a prescribed random surface yet requires a high degree of smoothness. This component is used to test adaptive optic systems.
The new formula that was used to develop the free-form-surface is more advantageous in regard to spot size and linearity than usual aspherical and troidal lens systems. However, the free form surface is much more complicated, compared to the usual optical system. Now, we would like to express the advantage of the free-form-surface design. We had to improve the nano CADCAM and compensation systems for the fabrication of injection molded plastic optics. In the future we plant to design a new optical system, now that the development of the one-piece f-theta lens has been completed. We describe the free-form optics now.
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