Feasibility of Verification and Evaluation on Optical Devices by 3D Printing Technology

Abstract

Abstract The intricate structural design of products within the optoelectronics industry plays a crucial role in achieving optimal optical outcomes. Consequently, the demand for precision plastic optical components has seen a notable rise in recent years. While injection molding technology remains the predominant method for fabricating plastic optical components, the market is currently trending towards features such as small-batch and diversified production, a streamlined development process, reduced costs, and swift delivery. This shift has prompted the industry to progressively move towards customization. Nevertheless, the conventional production model faces challenges related to production flow, mold cost assessments, expenses associated with hiring skilled professionals, and even a scarcity of talent. These challenges, in turn, have constrained the development of relevant industries. Against this backdrop, it is imperative to explore potential solutions that can swiftly replace traditional manufacturing processes in order to address these issues. In this study, we evaluated the feasibility of a headlight lens manufactured using a 3D printing process, incorporating a quality control (QC) inspection methodology. As a basis for comparison, we also employed a traditional manufacturing approach, utilizing CNC machining and reverse engineering. Diverse measurement techniques were applied, encompassing Coordinate Measuring Machine (CMM), Computer Aided Verification (CAV), White Light Interferometry (WLI), and Integrating Sphere, to analyze the radius of curvature, surface roughness, and transmittance of the headlight lens surface profile. These techniques were employed to validate the gathered data. The study results indicate that the lens products manufactured through 3D printing exhibit remarkable precision, with only a 0.558% margin of error regarding the radius of curvature of the profile, a surface roughness (Ra value) of 0.020175 µm, and a transmittance of 92.537%. One of the key advantages of the 3D printing process is its ability to efficiently realize complex structural designs at high speed and low cost. In cases where customization is required, 3D printing unquestionably outperforms conventional manufacturing methods. In this study, we have effectively addressed the issue of response time in traditional manufacturing processes by implementing rapid verification to accommodate various environmental demands.