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- 1. © WZL/Fraunhofer IPT
The “Production4μ” Project
Ultra precision production for optics and beyond
October 14th
Seminar Micro- en Precisiebewerkingen, Leuven,
Belgium
Sebastian Nollau
Fraunhofer IPT, Aachen, Germany
- 2. Page 1© WZL/Fraunhofer IPT
PresentationOutline
The Production4μ Project
The Precision Glass Moulding Technology
The Production4μ Process Chain
Precision Glass Moulding Cost Analysis
Conclusion
- 3. Page 2© WZL/Fraunhofer IPT
PresentationOutline
The Production4μ Project
The Precision Glass Moulding Technology
The Production4μ Process Chain
Precision Glass Moulding Cost Analysis
Conclusion
- 4. Page 3© WZL/Fraunhofer IPT
The Production4μ Project
General Budget distribution [Mio. €]
1,06
0,57
11,45
1,75 0,63
Research
Dissemination
Training
Demonstration
Management
Resources
Total Budget 15,43 Mio €
Total EC Funding 9,00 Mio €
Total man months 1306
May 2006 – October 2010
www.Poduction4micro.net
- 5. Page 4© WZL/Fraunhofer IPT
Work packages of Production4μ
Relevant Innovations
Reliable high volume
μ-manufacturing
technologies for
precision glass moulding
New systems
for automated handling
and alignment of
μ-components
New standards for μ-
production planning,
cost estimation and
“design for
manufacture”
Production4μ
Technologies4μ
Automation4μ
Methodologies4μ
glass
μ-handling
μ-alignment
μ-metrology
Key μ-components based on …
plastic
semi-
conductor
precision tooling
precision glass
moulding
μ-moulding
μ-manufacturing
standardization
Baugruppenebene 1
Zeitachse
ProduktprojeProduktstruktur
Komponentenebene 1
Ersteinsatzarchitektur
Derivatarchitektur
Ersteinsatzarchitektur
Derivatarchitektur
Projekt 1
Projekt 2
Architektur 1
FollowerArchitektur
Neuentwicklung Produkt 3 und Derivate
BaugruppenstrukturBaugruppenprojekte
Baugruppe 1
…
…
Projekt
Komponente A
Baugruppe 2
Komponentenebene 2
Baugruppe 4
Produkt 7
Produkt 6
Neuentwicklung Produkt 2
Baugruppeneben2 2
Derivat fü r die Serienpflege
Produkt 4
Produkt 5Prozesssynchropunkt
Zeitachse
Forschung
Projekt 1
Projekt 2
Projekt 3
Projekt 4
Baugruppe 5
Baugruppenebene 1
Zeitachse
ProduktprojeProduktstruktur
Komponentenebene 1
Ersteinsatzarchitektur
Derivatarchitektur
Ersteinsatzarchitektur
Derivatarchitektur
Projekt 1
Projekt 2
Architektur 1
FollowerArchitektur
Neuentwicklung Produkt 3 und Derivate
BaugruppenstrukturBaugruppenprojekte
Baugruppe 1
…
…
Projekt
Komponente A
Baugruppe 2
Komponentenebene 2
Baugruppe 4
Produkt 7
Produkt 6
Neuentwicklung Produkt 2
Baugruppeneben2 2
Derivat fü r die Serienpflege
Produkt 4
Produkt 5Prozesssynchropunkt
Zeitachse
Forschung
Projekt 1
Projekt 2
Projekt 3
Projekt 4
Baugruppe 5
μ-production planning
Launch- and quality
management
- 6. Page 5© WZL/Fraunhofer IPT
PresentationOutline
The Production4μ Project
The Precision Glass Moulding Technology
The Production4μ Process Chain
Precision Glass Moulding Cost Analysis
Conclusion
- 7. Page 6© WZL/Fraunhofer IPT
The precision glass moulding process
CoolingHeatingEvacuating and
flushing with gas
N2 gas
N2 gas
Moulding
force
Loading of glass preform into
moulding machine
Source: Fraunhofer IPT
Precision glass moulding
machine, Source: Fraunhofer
IPT / Toshiba
Moulding chamber within machine
Source: Fraunhofer IPT
Moulding tool with finished lens
Source: Fraunhofer IPT / Aixtooling
Advantages of the precision glass moulding process are high precision, very good repeatability,
ability to produce complex forms and low cost and resource-consupmtion.
- 8. Page 7© WZL/Fraunhofer IPT
High Precision Glass Moulding – Virtual Process Cycle
1. Loading and flushing
with N2
2. Heating up the inserts
and glass blank
3. Pressing the glass blank
N2 Gas
IR -Lamps
F
N2 Gas
4. Cooling down and
unloading the molded
lens
Process cycle
Tg
Time
Temperature
Force
Homogenization
Force
Temperature
Pressing
Heating up Cooling down
Temperature and force cycle
- 9. Page 8© WZL/Fraunhofer IPT
Material Requirements for High Precision Glass Moulding
Glass
- low transition temperature
- adapted CTE
- free from lead and arsenic
- low crystallisation affinity
- adapted temperature-viscosity
behaviour
Coating
- thickness homogeneity
- corrosion resistance
- crack resistance
- free of defects
- form stability
- thermal expansion
- abrasion resistance
- anti-sticking properties
Mould
- high form accuracy
- good machinability
- high material homogeneity
- high hardness
- high thermal conductivity
- high corrosion resistance
- 10. Page 9© WZL/Fraunhofer IPT
PresentationOutline
The Production4μ Project
The Precision Glass Moulding Technology
The Production4μ Process Chain
Precision Glass Moulding Cost Analysis
Conclusion
- 11. Page 10© WZL/Fraunhofer IPT
Complete process chain for the moulding of precision glass optics
Handling /
Automation
Handling /
AutomationMetrology
Metrology
Product
ProductAssembly /
Packaging
Assembly /
Packaging
Fisba
Ingeneric
VTT
Aixtooling
IPT
Schott
Ceratizit Aixtooling
IPT
KU Leuven
Ingeneric
LT Ultra
Cimatron
Fidia
Cemecon
IPT
Ceratizit
Schott IPT
Aixtooling
Fisba
Ingeneric
Fisba
IBS
Taylor
Hobson
WZL
KU Leuven
KTH
System3R
IPT
IPT
Penta HT
The full process chain is covered within the Production4μ project, requiring a large number of
partners.
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Work Package 2 WP 4 Work Package 3 DemoWork Package 1
- 12. Page 11© WZL/Fraunhofer IPT
Complete process chain for the moulding of precision glass optics
Design
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Optical
design
Mold
design
FE-Analysis
Mold and insert
dimensions
Insert quality (form
accuracy, roughness, etc)
R 1
2
Height
G
Thickness
R 2
Lens dimensions
Lens specifications (nd, , etc)
Lens quality (form accuracy,
scratch/dig, etc.)
Glass
Insert
12.5 µm
Glass shrinkage
Temperature, stress
- 13. Page 12© WZL/Fraunhofer IPT
Design
Compensation of Form Deviations by Process Simulation
Thermal shrinkage
dominates the form error
Squeeze force reduces the
form error significantly
Other factors build up
about 10% of the total
error, and may lead to
different amount at
different radius position
Form error compensation:
Development of a
simulation tool
Form deviation of pressed
lens with simulated tool is
±1 μm Radius position [mm]
-6
-4
-2
0
2
4
6 μm / deviation from desired form
0 2 4 6 8 10
Average of the calculation
Compensated tool
Pressed lens
Calculated deviation
After contact After 5 s After 30 s
- 14. Page 13© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Complete process chain for the moulding of precision glass optics
Raw Mould Tool Manufacturing
Tungsten Carbide substrate material with low binder content
Tungsten carbide with grain size < 200 nm and almost no
binder Co < 0,3 %
Interaction of this material with glass was analyzed.
No supplier in Europe before P4μ. Japanese manufacturers
offer this kind of materials and keep the production process
a secret.
- 15. Page 14© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Complete process chain for the moulding of precision glass optics
Mold Making
Grinding Polishing
UP - grinding
Single point grinding
Profile grinding
Polishing
2-dimensional
polishing
Zonal polishing
Diamond turning
Conv. diamond
turning
Ultrasonic assisted
diamond turning
Slow and fast tool
servo turning
Diamond
turning
- 16. Page 15© WZL/Fraunhofer IPT
A nano coating facility was established at Fraunhofer
IPT, specializing on optical coatings.
As most promising coatings have been identified by
moulding tests:
DLC, CrN, TiAlN and Pt/Ir
Coating thickness: ~300nm
Noble metals reduce chemical interactions
Challenges
– Preservation of surface quality
– Coatings for different mold materials and glasses
– Increased and predictable coated tool lifetime
2 μm
Coating process
300 nm PtIr coating
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Complete process chain for the moulding of precision glass optics
Mold Coating
- 17. Page 16© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packagin
Assembly /
Packagin Product
Product
Complete process chain for the moulding of precision glass optics
Glass and Preform Manufacturing
Ultra Low Tg glass P-SK56
– Glass optimized and successfully pressed inhouse. Still in
work: coating compatibility test / climate test, „re-pressing“ and
repressing for final qualification.
Ultra Low Tg glass P-SK58 (L-BAL35)
– One version with Tg < 390°C, two others with improved chem
res. and Tg < 410°C developed. Two of the 3 versions successfully
precise pressed inhouse. Further tests, see P-SK56.
Development and test processes for Low Tg
– Test processes have been optimized to fit to the special
requirements of Low Tg glasses. For the last period, coating and
climate tests are planned, which are the most crucial for ultra
Low Tg.
- 18. Page 17© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Complete process chain for the moulding of precision glass optics
Precision Glass Moulding
Molding test of new glasses
– Several melts of new glass material were evaluated in
molding tests regarding suitability for glass molding and
changes in surface quality.
Molding of diffractive structure
– Complete diffractive structure with optical function
was molded in low Tg glass with nickel silver moulds.
- 19. Page 18© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Complete process chain for the moulding of precision glass optics
Metrology
Chromatic Sensor
Scanning Measurement
Method
Best fit radius
Error Maps Source: FRT GmbH
White light interferometer
Surface topography
Roughness
Form Accuracy for micro-
scale parts
Tactile measurement device
Form accuracy
Best fit radius
Absolute radius
Source: Veeco Source: Taylor Hobson
Accuracy
check
Roughness
check
- 20. Page 19© WZL/Fraunhofer IPT
Metrology
Highlight Activities and Results
Profilometry for steep-sided optics
Taylor Hobson developed a tactile metrology device for
measuring steep-sided aspheric optics and moulds. The system can
measure slopes up to 85 degrees (with a tilted traverse unit).
Machine integration of interferometric measurement system
First interferometric measurements were carried out on the
machine. To reduce the impact of external disturbances,
modifications were realised by implementing software algorithms
in order to decrease the measurement time.
Realised pre-prototype of miniaturised tactile probe system
IBS has realised a prototype of a new tactile probe system in order
to measure smaller and more complex products.
- 21. Page 20© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Complete process chain for the moulding of precision glass optics
Handling, Automation, Assembly and Packaging
Assembly /
Packaging
Assembly /
Packaging Product
Product
Objectives
Automation solutions for ultra precision machining
Automated work piece alignment as well as automated tool exchange
and alignment
Handling and clamping of ultraprecise work pieces are addressed
Test benches
Reference station
Active work piece alignment device
Automated work piece alignment on vacuum spindles
Tool exchange system for UP-lathe
Exchange system for rotating tools
Direct work piece transfer and handling
Clamping of pre-shaped parts
Gripper for direct work piece alignment
Active alignment of work pieces for
ultraprecision milling and grinding
Automated tool
alignment for
diamond turning
Transport box for
long distance work
piece transfer
- 22. Page 21© WZL/Fraunhofer IPT
Automation4μ
Need for Automation in Ultraprecision Mastering and Mould Making
Optics Design ReplicationMetrology
Optical design and
specifications
CAD mould
modelling
NC program
generation
1. Quality loop
2. Quality loop
Correction of tool path
Correction of mould design
Mastering and
Mould Making
Tool and work
piece referencing
Diamond
machining
Ultraprecision
grinding
Tactile and optical
measurement of
mould inserts and
lenses
Data handling
(generation of
error maps)
Shrinkage
simulation and
compensation
Adjustment of
moulding
parameters
Automation interfaces
Automation interfaces
- 23. Page 22© WZL/Fraunhofer IPT
Automated tool set upAutomated work piece alignment
Automation4μ
Automation Equipment which is developed within Work Package 3
Automated handling
Transport box for
long distance work
piece transfer
Gripper
for direct work
piece handling
Active alignment of work pieces for
ultraprecision milling and grinding
Automated centring of
rotational symmetric work pieces
Active alignment balancing of
fly-cutting spindles
Automated tool alignment
for diamond turning
Automation4μ:
Fully automated handling
of tools and work pieces in
ultraprecision machining
Increase of accuracy
Increase of efficiency
Increase of quality
- 24. Page 23© WZL/Fraunhofer IPT
Automation4μ - Active Work Piece Alignment
State of the Art – Set-up for Linear Structuring Processes
Set-up procedure:
Distortion free clamping of the
work piece (e.g. with screws,
vacuum, adhesives)
Determination of the surface
topography and leveling out
of the work piece
Referencing: Alignment of the
tool towards the work piece
(e.g. by scratch mark)
Set-up precision:
5 – 20 μm
Set-up time:
Up to 1 hr
Deficits:
Manual alignment capabilities
Visibility of the scratch mark
Material allowance is needed
to compensate for work piece
clamping and referencing
inaccuracies
Pre machining of the
raw work piece
Manual tilt alignment
of the work piece
Micro grooves in an
ultraprecision machined surface
- 25. Page 24© WZL/Fraunhofer IPT
Automation4μ - Active Work Piece Alignment
Active Work Piece Alignment – Final Design
xy
z
Optical detection of
the reference mark position
Active
alignment
device with optical
referencing system
Referencing of work pieces to
standardized System 3R
pallets prior to machining
Indirect in-machine
referencing of the work pieces
by optical detection (CCD
cameras) of the pallet position
via reference marks
Active compensation of the tilt
offsets using high resolution
piezo actuators in combination
with flexure joints
Compensation of the
translational offset by
forwarding the residual offsets
to the NC of machine-tool
control
Targeted precision < ± 0.25 μm
- 26. Page 25© WZL/Fraunhofer IPT
Automation4μ - Active Work Piece Alignment
Technical Specifications of the Active Alignment Device
Actuators:
PI P237.30
Travel range +/-20 μm
Resolution: 2 nm
CCD-Cameras:
Allied Vision Technology
GUPPY F-146B
1/2" IT-CCD Progressive-Scan
Sensor
Picture size: 1392 x 1040 pixels
Pixel size 4.65 μm x 4.65 μm
Objectives:
SILL TZM-FO MINI 8465/4,0
Magnification: 4:1
Field of view: 1.6 x 1.2 mm²
Depth of focus: 0.13 mm
Working distance: 64.5 mm
Software:
IPD »SHERLOCK«
Resolution: ± 0.15 μm
Photo image of a reference mark
Active work piece
alignment device
with piezo acutators
and CCD cameras
Recording of the reference mark
positions with the »Sherlock« software
- 27. Page 26© WZL/Fraunhofer IPT
Automation4μ - Active Work Piece Alignment
Machine Integration of the Active Chuck and Alignment Procedure
x1, y1
x2, y2
x3, y3
θx
θy
Reference data:
Px, Py, Pz, θx, θy, θz
Set point
calculation
Determination of the work
piece position on the pallet in
relation to the reference
marks -> generation of
reference data
Read out of reference data
after clamping the pallet at
machining site
Retrieval of pallet position
data from CCD Cameras
Set point calculation and
generation of control signals
for active alignment chuck
Levelling out of the work
piece
Check of the reference marks
on the pallet
Tool alignment using
compensation coordinates
provided by set point
algorithm
x, y, z, θz
Fidia
CNC
- 28. Page 27© WZL/Fraunhofer IPT
Automation4μ - Active Work Piece Alignment
System 3R »MacroNano« Chuck
System 3R provides high precision palletized work piece clamping
systems based on the principle of elastic averaging
For conventional machining the System 3R »Macro« chuck enables a
work piece relocation accuracy of ± 2 μm within the global machine-
tool coordinate system
The System 3R »MacroNano« chuck is based on the design and the
functionality of the conventional »Macro« chuck
Advanced understanding and expertise in design, materials and
processing technology allow for a further improvement of the
relocation accuracy of the pallet:
– Pre-machining of the rigid contact surfaces on the chuck and the
pallet through high precision grinding
– Finishing of the interfaces by lapping operation
Advanced pallet design avoids sub-micron deflection due to clamping
forces
Features of the »MacroNano« chuck:
Relocation of the work piece within ± 0.5 μm
Indexing of the work piece at 90° with four indexing positions
System3R
»MacroNano« chuck
Work piece pallet with
flexible references
- 29. Page 28© WZL/Fraunhofer IPT
Automation4μ - Active Work Piece Alignment
New Perspectives in Production Enabled by the Active Alignment Chuck
Continuous level of quality of
ultraprecision machined work
pieces
No material allowance is
needed to compensate for
alignment errors
Reduced set up time for
ultraprecision machined
processes
New Products
Serial production of
ultraprecision machined
moulding and stamping tools
Mass production of high
precision micro system
components
New Processes
Ultraprecision finishing of pre
machined steel parts with thin
nickel coatings (< 100 μm)
Steel work piece with 100 μm
nickel coating
V-grooves in an amorphous
nickel layer
10 μm
250 µm
2 – D Fibre array composed out
of carrier plates with passive
alignment structures for
light guides
Single carrier
plate with
mounted
light guides
- 30. Page 29© WZL/Fraunhofer IPT
Automation4μ - Active Tool Alignment
Automation Approach - Tool Exchange System for UP-Turning
Realisation:
Tool magazine and handling
Measuring of tool position and
angular orientation
Automated correction of
misalignment in sensitive DOF
Environment:
Precitech Nanoform 350
Hydrostatic linear axes: X, Z
Aerostatic spindle
Main components:
Active tool alignment device
Tool magazine and handling
system
Tool referencing station
Machine base
Alignment unit
X-Slide
Tool magazine
Z-Slide
Spindle
Measurement systemMachine housing
- 31. Page 30© WZL/Fraunhofer IPT
Automation4μ - Active Tool Alignment
Active Tool Alignment Device
Drive for
tilting
(A-Axis)
Tool
holder
Drive for
height
adjustment
(Y-Axis)
Tool release
cylinder
Clamping and alignment of
tools (three degree of
freedom)
A-axis (rake angle adjustment)
– Stroke: +/- 1°
B-axis (tool orientation)
– Stroke: -5° < b < 95°
(110°)
Y-axis (height adjustment)
– Stroke: 2,5 mm
– Accuracy: 0,2 μm
Base
Rotary
table
(B-Axis)
Linear
guides
Z-Slide
CAD-Model
- 32. Page 31© WZL/Fraunhofer IPT
Automation4μ - Active Tool Alignment
Tool Magazine and Handling System
Swivel axis
Linear motion
Tasks of tool exchange system
– Storage of two tools
– Realization of tool
handling
Operated automatically by PLC
of control unit
Clamping accuracy of HSK
(measured at tool tip):
+/- 1 μm
- 33. Page 32© WZL/Fraunhofer IPT
Automation4μ - Active Tool Alignment
New Perspectives in Production Enabled by the Automated Tool Alignment
Backlight system using diffractive structures
10 μmNew Products
Microstructured films for
LED-backlight systems
Precise and burr-free
diffractive optics
New Processes
Machining and structuring
of drums and rollers with
different structure and
tool geometries
Machining of drums
Spindle
Drum
Tool alignment
unit
Z-slide Drum with v-grooves
- 34. Page 33© WZL/Fraunhofer IPT
Design /
Simulation
Design /
Simulation Raw Tool
Raw Tool Precision
Machining
Precision
Machining Coating
Coating Glass/
Preform
Glass/
Preform Moulding
Moulding
Metrology
Metrology Handling /
Automation
Handling /
Automation
Assembly /
Packaging
Assembly /
Packaging Product
Product
Complete process chain for the moulding of precision glass optics
Final Product: Production4μ Demonstrator Products
Aspheric
feature
Cylindric
feature
Diffractive
feature
PV Ra PV Ra PV, Ra
step
height
May2008
Aspheric micro
lense
Cylinder lense
array
Diffractive
aspheric lense
October
2010
Feature-based demonstrators
Product-based demonstrators
Similar systems and
components for other
applications
aspect ratio
aspect ratio
Transfer
tootherμ-areas
Microfluidics
ScopeofProduction4μIP
- 35. Page 34© WZL/Fraunhofer IPT
Production4μ Demonstrator Products
-Rot.- symmetric
(aspherical)
Cylindrical
(asph./asph.)
microstructured
(diffractive optical
elements)
DEMO 1 by Ingeneric
Aspherical-spherical lens
Glass material: P-LASF47
Form specifications:
3/ 3(0.5) @1030nm
for sphere and asphere
Surface defects:
5/ 5 x 0,063
L6x0,0025 (max. ¼ Ø)
for sphere and asphere
DEMO 2 by FISBA
Double side aspherical cylinder
lens array
Glass material: P-LASF47
Form specifications:
3/ < 0.1 μm RMS
Surface defects:
5/ 5x0.04
DEMO 3 by VTT
Aspheric-diffractive lens
Glass material: P-SK56
Specifications:
< 10 % step height difference
Ø 27
4
R 0.3 apex rad.
0.35355
±
0,0003
P-SK56
- 36. Page 35© WZL/Fraunhofer IPT
Update
Demonstrator Usage and Application
-Rot.- symmetric
(aspherical)
Cylindrical
(asph./asph.)
microstructured
(diffractive optical
elements)
DEMO48-1 by Ingeneric
Focussing of high-power
laser beams (applications
similar to DEMO 48-2)
Usage of plastic lenses
impossible due to high
power densities
Until now, only Quartz glass
has been used
Similar lenses are relevant
for imaging optics
DEMO48-2 by FISBA
Laser beam symmetrization for
high power diode lasers
Industrial applications: Cutting,
Writing, Welding, etc.
Application in medical
technology
DEMO48-3 by VTT
Improved image quality with
less lens elements
High Quality Photography
Optics
Mobile Phone Cameras
Medical Imaging and Metrology
- 37. Page 36© WZL/Fraunhofer IPT
PresentationOutline
The Production4μ Project
The Precision Glass Moulding Technology
The Production4μ Process Chain
Precision Glass Moulding Cost Analysis
Conclusion
- 38. Page 37© WZL/Fraunhofer IPT
How does the new technology compare to conventional processes?
Resource advantages of precision glass moulding
Energy
Water
Raw Material
Milling PolishingGrinding
Precision
Glass
Moulding
Energy consumption of precision glass moulding compared to conventional optics production
Precision glass moulding
requires electricity for
heating and pressing, but
has a low resource
consumption other than
that.
The conventional process
chain requires water and /
or lubricants for all steps
and removes waste raw
material, while also
consuming electricity.
The reduction of the number of process steps from three to one, which is additionally less
resource consuming, enables a large saving of resources.
Source: resource calculation / estimation of Fraunhofer IPT within the Production4μ project
- 39. Page 38© WZL/Fraunhofer IPT
0%
50%
100%
150%
200%
250%
100 1000 10000
Production Volume
ProductionCost
Replicative
Non-replicative
100 % base
The calculation for one example
product is shown, calculations for
variuos sample products yielded
similar results.
The production was assumed to take
place in Europe (Germany).
However, similar values will also be
correct for Asian production facilities
since the main share of costs is not
caused by personnel, but by expensive
machines and tools.
The break-even for moulding versus non-replicative manufacturing is located between 500 and
800 pieces of production volume.
A break-even on a resource-only level of comparison is even reached at smaller numbers.
Cost comparison of non-replicative and replicative
manufacturing*
*replicative: Precision glass moulding
non-replicative: typically milling, grinding and polishing
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What is the status of the new technologies’ usage?
Current industrial usage of the precision glass moulding technology
0
20
40
60
80
100
geometry
functional
configuration
diameter
curvature
spectralrange
application
Percentage of
total sales (%)
Suitablefor
moulding
regarding…
Polished glass 81%
Plastic
Moulded glass 1%
Others
10%
8%
Percentage of moulded glass lenses in optics
sales of the study participants
Percentage of products that could potentially be
produced with glass moulding
Results of a survey of the German optics industry by Fraunhofer IPT and Spectaris
Very low share of optics that were produced with
precision glass moulding!
While the number of optics produced by precision glass moulding is still very low, the potential
for this technology is very high.
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PresentationOutline
The Production4μ Project
The Precision Glass Moulding Technology
The Production4μ Process Chain
Precision Glass Moulding Cost Analysis
Conclusion
- 42. Page 41© WZL/Fraunhofer IPT
Conclusion
Precision glass molding allows for:
Shortening the process
Shorter lead times
Lower costs and resource consumption
Forming all surfaces of complex shaped optical
elements in one process step (asphere, cylinder
array etc.)
High form accuracy (/4 - /8) combined with
high reproducibility of molding results
Precision glass moulding has a large industrial
potential.
The Production4μ project aims at developing
solutions to help industry access this potential.
Your Contact:
www.production4micro.net
Fraunhofer IPT
Sebastian Nollau
sebastian.nollau@ipt.fraunhofer.de
Tel. +49 241 8904 271
- 43. Page 42© WZL/Fraunhofer IPT
Information on Upcoming Event
The colloquium will focus on three topics:
Strategy and Markets
Technology and Production
Products and Innovation
Programme
Two-day conference with speakers from industry and
research
Social program: conference dinner,
shop floor visit at Fraunhofer IPT and Fraunhofer ILT
Conference venue: Pullman Aachen Quellenhof
Information
www.optik-kolloquium.de
6th International Colloquium on Optics
October 19 and 20, 2010 in Aachen