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Applied Optics

Applied Optics

APPLICATIONS-CENTERED RESEARCH IN OPTICS

  • Editor: Joseph N. Mait
  • Vol. 53, Iss. 24 — Aug. 20, 2014
  • pp: 5264–5274

Determination of injection molding process windows for optical lenses using response surface methodology

Kuo-Ming Tsai and He-Yi Wang  »View Author Affiliations


Applied Optics, Vol. 53, Issue 24, pp. 5264-5274 (2014)
http://dx.doi.org/10.1364/AO.53.005264


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Abstract

This study focuses on injection molding process window determination for obtaining optimal imaging optical properties, astigmatism, coma, and spherical aberration using plastic lenses. The Taguchi experimental method was first used to identify the optimized combination of parameters and significant factors affecting the imaging optical properties of the lens. Full factorial experiments were then implemented based on the significant factors to build the response surface models. The injection molding process windows for lenses with optimized optical properties were determined based on the surface models, and confirmation experiments were performed to verify their validity. The results indicated that the significant factors affecting the optical properties of lenses are mold temperature, melt temperature, and cooling time. According to experimental data for the significant factors, the oblique ovals for different optical properties on the injection molding process windows based on melt temperature and cooling time can be obtained using the curve fitting approach. The confirmation experiments revealed that the average errors for astigmatism, coma, and spherical aberration are 3.44%, 5.62%, and 5.69%, respectively. The results indicated that the process windows proposed are highly reliable.

© 2014 Optical Society of America

OCIS Codes
(080.1010) Geometric optics : Aberrations (global)
(080.2205) Geometric optics : Fabrication, injection molding

ToC Category:
Geometric Optics

History
Original Manuscript: May 21, 2014
Revised Manuscript: July 7, 2014
Manuscript Accepted: July 8, 2014
Published: August 11, 2014

Citation
Kuo-Ming Tsai and He-Yi Wang, "Determination of injection molding process windows for optical lenses using response surface methodology," Appl. Opt. 53, 5264-5274 (2014)
http://www.opticsinfobase.org/ao/abstract.cfm?URI=ao-53-24-5264


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