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Shape Memory Molding: a New Method for Fabricating Polymer Optics

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Shape Memory Molding: a New Method for Fabricating Polymer Optics 1st International Conference on on Optics, Photonics and Lasers (OPAL' 2018) 9-11May 2018, Barcelona, Spain Shape Memory Molding: A New Method for Fabricating Polymer Optics W. D. Liu 1 and L.C. Zhang 1 1 Laboratory for Precision and Nano Processing Technologies, School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW, 2052 Australia Tel.: +61 2 93856078, fax: +61 2 96631222 E-mail: [email protected] Summary: This paper reports a new molding technique for fabricating polymer optics based on the shape memory property of poly(methyl methacrylate) (PMMA). Different from traditional thermoforming techniques that require expensive and time-consuming moulding process, this technique only needs a programmed PMMA sample, a mold, and a furnace. Particularly, in this paper a programmed PMMA sample was prepared via high-temperature compression; a mold with micro-lens array cavities was fabricated by an ultra-precision machining center; shape memory molding was conducted at high temperature without applying any external force. It was found that after the programming process, significant residual stress was stored in the PMMA sample, which can be characterized by a polariscope. During the shape memory moulding process, the residual stress could be released, and the sample expanded and filled the die cavities. The profile of the moulded micro-lens arrays was charactered by a white light interferometer system. Keywords: Shape memory molding, polymer optics, residual stress, PMMA, microlens array 1. Introduction transition temperature is 105 ˚C. Circular samples with a thickness of 2.6 mm and a diameter of 7 mm Polymer optics are widely used in optical devices were cut from the raw material plate and polished by due to their low cost of materials, high production #2000 sandpaper. volume and high impact resistance. Generally In the programming process, the sample was first polymer optics are fabricated by thermoforming/hot placed into a glass moulding machine (GPM-211) embossing [1]. In a typical thermoforming process, a with a pair of flat heads. Then the sample was heated polymer sample is placed into a precision forming to 140 ˚C. After 5 min soaking time, the sample was machine with a well-prepared die, heated to target pressed by the upper flat head at a constant speed of 1 moulding temperature, and then accurately pushed mm/min. When the thickness of specimen was towards the die cavities to form the final optical reduced to 1.7 mm, the head stopped moving and the features. However, due to the long cycle time and cooling stage was started. Its residual stress was limitations of die fabrication and installation, its the characterized by a polariscope analyzer (LSM production rate is low. 9000W). Some polymer optical materials possess thermal- In the subsequent molding process, the lower flat induced shape memory effect, such as poly(methyl die in the moulding machine was replaced by a die methacrylate) (PMMA) [2, 3]. In brief, at a high with micro lens array cavities. This die is fabricated temperature above Tg (glass transition temperature), from an NI-P plated nickel alloy by ultra-precision polymer glass network demonstrates superelasticity machining center (Nanotech 350FG). The and can be deformed to a particular shape. While programmed sample was placed between the new die holding the pressure in the cooling process, that shape and the upper flat head. To avoid the effect of thermal can be fixed at room temperature. The whole process expansion, a small gap (< 0. 5 mm) was arranged above is called shape programming. If one heat the between the top surface of the sample and the bottom programmed sample back to that temperature, the of the upper flat die. The sample was then heated up sample can recover back to its original shape. to 140 ˚C and soaked for 5 min. It is expected that the This paper aims to develop a new molding shape memory property of the programmed sample technique based the shape memory property of will automatically fill the gap and copy the micro-lens polymer glass. Instead of using expensive presicion array feature. After cooled back to room temperature, molding machine, the new molding technique only the thickness of the sample becomes 2.2 mm. needs a programmed PMMA sample, a mold, and a After moulding, the surface profile of the PMMA furnace. Particularly, the moulding process will be sample was charaterized by a white light conducted without applying any external force. The interferometer (Zygo NewView 700 ). moulded microlens array will be characterized. 3. Results and Discussion 2. Methods 3.1. Polariscopy images of PMMA samples Raw PMMA material is provided by Palram Australia PTY LTD (Suntuf brand). Its glass Figure 1 shows the optical retardation distribution of PMMA sample before and after programming 1st International Conference on on Optics, Photonics and Lasers (OPAL' 2018) 9-11May 2018, Barcelona, Spain process. The magnitude of retardation is proportional with those of the designed lens array, proving that the to the difference of principal stresses [4]. In the raw shape memory molding is successful. material (Fig. 1a), the retardation values are very small and uniform, indicating a low internal stress. One can find some high retardation value near the edge of the circular sample. This is due to the edge effect and does not reflect the real stress state. After programming (Fig. 1b), the optical retardation (residual stress) increased a lot, particularly the annulus zone near center. After further shaping memory moulding (Fig. 1c), the retardation decreased significantly, indicating that the internal residual stress was released. Therefore, these polariscopy images clearly reveal the store and release of residual Fig. 2. The moulded lens array characterized by a white stress during the programming process and moulding light interferometer. process, respectively. Fig. 3. Profile comparison of a representative lenslet. 4. Conclusions This paper proposed a new moulding method for fabricating micro-optics based on the shape memory property of polymer. This technique can be divided into two steps: (1) programming and (2) shape memory moulding. The polariscope analysis clearly shows the store and release of internal residual stress during these two steps, respectively. Further profile characterization proved that the method of shape memory molding is successful. Acknowledgements This work was sponsored by an discovery project, DP140103476, of the Australian Research Council. Fig. 1. Optical retardation (unit: nm) in the PMMA References sample (a) before programming, (b) after programming and (c) after moulding. [1]. Heckele M, and Schomburg W K, Review on micro molding of thermoplastic polymers, J Micromech 3.2 Charaterizations of PMMA after moulding Microeng, 2004, 14: R1-R14. [2]. Zhou Y, and Huang W M, Shape memory effect in Figure 2 shows the surface profile of PMMA polymeric materials: mechanisms and optimization, sample after moulding, in which the color scale Proc Iutam, 2015: 83-92. represents the surface height. One can clearly see the [3]. Schneider N, Zeiger C, Kolew A et al., moulded micro-lens arrays. Figure 3 shows the profile Nanothermoforming of hierarchical optical comparison between the moulded lenslet and the components utilizing shape memory polymers as active molds, Opt Mater Express, 2014, 4: 1895- designed one. The diameter and height of a 1902. representative lenslet are about 150 μm and 1 μm, [4]. Magalhaes P A A, Magalhaes C A, and Magalhaes A respectively, and the distance between two lenslets is L M A, Computational methods of phase shifting to about 150 μm. All these dimensions match very well stress measurement with photoelasticity using plane polariscope, Optik, 2017, 130: 213-226. .
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